Cover Page - NP Series - Seresco Dehumidifiers

Installation, Operation & Maintenance Manual

For the latest updated versions of this or other Seresco

Installation, Operation & Maintenance Manuals contact Seresco Technologies Inc. Tel: (613) 741-3603

Visit: www.serescodehumidifiers.com

Issue Date : 2011-09-30

NP Series Dehumidifiers

Issue Date : 2011-09-30

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2

Issue Date : 2011-09-30 Table of Contents

Section Section Title Page(s)

A Warnings, Cautions and Notices

Warnings, Cautions and Notices A-1

Refrigerant Handling Practices A-1

B NE/NP/NV Series General Information

General Information B-1

Unit Description B-1

Component Descriptions B-2

Product Nomenclature B-7

Unit Label B-11

Further Information B-12

C Pre-installation Requirements

Pre-installation Requirements C-1

Receiving Checklist C-1

Shipping Damage Instructions C-1

Storage C-2

D Mechanical Installation

Mechanical Installation D-1

Lifting and Rigging Procedures D-1

Unit Assembly D-1

Duct Connections D-1

Piping and Unit Connections D-2

Drain Pans – Condensate Drain D-2

Blower Motor Brace D-3

Field Installed OACs D-4

Factory Start-up Supervision D-7

E Electrical Installation

Electrical Installation E-1

Main Panel Power Connection E-1

Control Wiring E-2

Websentry Connection E-3

Remote Operator Panel E-4

Table of Contents Issue Date : 2011-09-30

F Start-up

Start-up F-1

Pre-Startup Checklist F-1

Start-up Procedure F-3

Factory Start-up Supervision F-6

G NE/NP/NV Series Operation

Sequence of Operation G-1

CommandCenter Operation G-5

H Routine Maintenance

Routine Maintenance H-1

Routine Maintenance Checklist H-1

Component Maintenance H-2

Refrigerant Charging Procedure H-4

Outdoor Air Balancing H-7

Mechanical Vestibule Access Steps H-9

X Troubleshooting

Troubleshooting X-1

Troubleshooting Steps X-1

Contacting Service and Technical Support X-1

Websentry Troubleshooting X-2

Y Warranty

Warranty Y-1

Z Annex

Issue Date : 2011-09-30 Section A - Warnings, Cautions and Notices

Warnings, Cautions and Notices

Throughout this manual, warnings, cautions and notes appear when special care must be taken to avoid potential hazards

that could result in mechanical or electrical damage, personal injury or death.

WARNING Indicates a potentially hazardous situation which could result in serious injury or

death if handled improperly.

CAUTION Indicates a potentially hazardous situation which could result in moderate injury or

equipment damage if handled improperly.

Note : Indicates a situation that could result in equipment damage if handled improperly.

Refrigerant Handling Practices

Refrigerants composed of chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs) have a catastrophic effect on

the earth's protective ozone layer when released to the atmosphere. Seresco Technologies Inc. advocates the responsible

handling of all refrigerants. Consult the appropriate Material Safety Data Sheets (MSDS) for further information. Follow all

laws in your area that apply to the handling, reclaiming, recovering and recycling of refrigerants and associated equipment.

WARNING System contains oil and refrigerant under high pressure. Recover refrigerant to relieve

pressure before opening the system. Refer to the unit label to determine the refrigerant type. Do not use

non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper

procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could

result in death, serious injury or equipment damage.

WARNING Use only dry nitrogen with a pressure regulator for pressurizing the unit. Do not use

acetylene, oxygen, compressed air or mixtures of the aforementioned for pressure testing. Do not use

fixtures of a hydrogen-containing refrigerant and air above atmospheric pressure for pressure testing as

they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should

only be mixed with dry nitrogen for pressurizing units. Failure to follow these recommendations could

result in death, serious injury or equipment damage.

A-1

Section A - Warnings, Cautions and Notices Issue Date : 2011-09-30


A-2

Issue Date : 2011-09-30 Section B - NP Series General Information

General Information

Use this manual to install, operate and maintain your Seresco Technologies Inc. (Seresco) NP Series dehumidification unit.

Carefully review the procedures and instructions in this manual to minimize installation and operation difficulties. Every

Seresco dehumidification unit is accompanied by a label that identifies the unit serial number, mechanical, refrigeration and

electrical operating information. This information is required when ordering parts or requesting service for a Seresco

dehumidification system. Seresco also publishes a comprehensive natatorium design guide which provides a wealth of

information on how to design a pool. See www.serescodehumidifiers.com for more information.

Unit Description

Seresco's NP Series advanced dehumidifiers are designed for residential or commercial indoor pools and other various

dehumidification requirements. The unit is comprised of components such as fans, compressors, refrigeration coils, filters,

dampers and pumps. The NP Series units reject heat to a glycol-water loop through two flat plate heat exchangers instead of

through a condenser coil. This allows for a system which requires substantially less refrigerant charge than a standard NE

Series unit. The heat transferred to the glycol-water solution is then rejected through a condenser coil located in the unit and

an outdoor air fluid cooler (OAFC).

Figure B-1. Typical refrigeration circuit for NP Series units

B-1

Section B - NP Series General Information Issue Date : 2011-09-30

Component Descriptions

The following components are commonly used on Seresco Technologies Inc.'s NP Series of dehumidifiers. Detailed

technical information can be found in the annex and in the respective manufacturer's IOM manual(s).

Check Valves

A single direction flow valve, typically installed on the discharge line of the compressor and used to prevent back-flow of

liquid refrigerant. Extends the life of the compressor.

ORD/ORI Valves (R-407C) or LAC Valve (R-410A)

Head pressure control valves, used as a means of controlling head pressure in the refrigeration system. Can either be fixed or

manually adjustable. By keeping the head pressure at stable conditions, the efficiency of the system increases.

Solenoid Valves

Two-way valves used as a means of controlling refrigerant flow through the system depending on mode of operation (e.g.

Air conditioning, or reheat).

Thermostatic Expansion Valve

Precisely selected to provide optimal refrigerant flow to the evaporator coils and factory adjusted to maintain superheat

conditions within 18-20 °F.

Ball Valves (2-way and 3-way)

Manual two-way valves are used as shut-off valves, most commonly used to shut off refrigerant flow to allow field

installation of remote condensers. Actuated three-way valves used to modulate flow when in different modes of operation.

Rotolock Valves

Manual shut-off valve used to isolate the compressor(s) and receiver to allow ease of serviceability and component

replacement.

B-2


Plate Heat Exchanger

Plate heat exchangers are compact in size and efficient at exchanging waste refrigerant heat to a secondary fluid loop. This

secondary fluid is then pumped to a fluid cooler or internal water coil.

Co-axial Heat Exchanger

Used as a condenser to exchange waste refrigerant heat to the pool water.

Receiver

Stores liquid portion of the refrigerant charge. They are equipped with external sight glasses to allow the refrigerant level to

be monitored. If the bottom sight glass is not floating, the system is undercharged. If the top sight glass is floating high, the

system is overcharged.

Suction Accumulator

Used to trap any potential liquid flood-back to the compressor, prolonging system life.

Filter Drier

Keeps moisture out of the system and contains potential contaminants that have entered the refrigeration system. Larger

units are equipped with removable filter-drier cores for ease of serviceability.

High / Low Pressure Switches

Hi/Lo pressure switches are installed as a safety mechanism to prevent the system pressures from leaving the normal

operating range.

B-3


Figure B-2. Pressure transducer (3-wire) and switch (2-wire)

Oil Safeties

Safety device to monitor oil levels in the system. Proper oil levels in the compressor are vital to its proper operation and life.

Figure B-3. Example oil safety, actual model may vary

Relief Valve

Installed on liquid receivers and used as an emergency pressure release. Opens if component's maximum allowable pressure

is reached in the system to prevent damage.

Flow Switch

Safety device used to trigger a no water flow fault if no fluid flow is detected.

B-4


Sensors

Sensors mounted within the unit are key to Seresco's control systems which are capable of running the system without

human intervention.

Relative Humidity

Located between the filters and evaporator coil(s), measures the relative humidity of air entering the unit from the pool

space.

Temperature

Stainless steel sensors mounted throughout the unit to provide temperature data to the automated controls system. Sensors

measure the temperature of air leaving the evaporator coil(s), air being exhausted from the unit, air brought in from the

outdoors, and air returning to the pool space.

Figure B-4. Pool water sensor Figure B-5. Sensor in well Figure B-6. Evap coil sensor

Additionally, sensors mounted in copper wells determine the suction and discharge refrigerant line temperatures. On units

with pool water heating, pool water temperature is recorded both when entering and leaving the co-axial heat exchanger.

B-5


Pressure Transducers

Figure B-7. Pressure switch (2-wire) and transducer (3-wire)

A low pressure transducer measures pressure on the suction line, while a high pressure transducer measures the pressure on

the (compressor) discharge line.

Product Nomenclature

The product nomenclature is a 27 character alpha-numeric sequence that completely describes the options present on the

dehumidification unit.

Table B-1. Seresco Technologies Inc. Nomenclature Definition Version 3.2

Series

Natatorium Environmental Control Series NE

Natatorium Protocol Series NP

Natatorium Ventilation Series NV

Dash Dash -

Tonnage

2 ton 002

...16 ton 016

18 ton 018

...80 ton 080

10 ton “double decker” 210

...32 ton “double decker” 232

Dash Dash -

Pool HeaterNo Pool Water Heater N

Pool Water Heater P

Cabinet

Configurations

Double walled - Return plenum - Bottom B

Double walled - Horizontal Return C

Horizontal -single wall Standard H

B-6


Horizontal - single wall - Mirrored M

Vertical - single wall Mirrored N

Double walled - Return plenum - Right Side R

Double walled - Return plenum - Left Side S

Double walled - Return plenum - Top T

Vertical - single wall Standard V

Special Z

Dash Dash -

Indoor/OutdoorIndoor Unit I

Exterior Unit X

Dash Dash -

AC Options

Outdoor Air Cooled Condenser A

Glycol Cooled By a Fluid Cooler G

Air Handler (Chilled Water Coil) H

Water Cooled - Variable Flow (< 65F Water Loop) M

No Air Conditioning (All AC components removed) N

Packaged/Integral Air Cooled Condenser P

Water Cooled - Variable Flow (70-85F Water Loop) V

Outdoor

Air Options

None 0

Duct Connection Collar Only 1

Duct Collar c/w Manual Damper & Filter 2

OA Inlet Motorized Damper & Filter 3

Purge/Economizer Motorized Damper (In addition to OA Motorized Damper Option) 4

Heat Recovery Package with Motorized Damper and Time Clock 5

Heat Recovery Package Option on OA with Additional Purge/Economizer Option 6

Exhaust Fan

Unit mounted Exhaust fan (Required with HR) E

Unit mounted Exhaust fan and Purge/Economizer Fan F

None N

Unit mounted Purge/Economizer Fan P

Supply Air

Orientation

Bottom Supply B

Top Right Supply D

Horizontal - Loopback E

Top Loopback End Supply F

Top Left Supply G

Horizontal (Straight Through) H

Top Horizontal End Supply J

Left (oriented with airflow air turns left out of unit) L

Right (oriented with airflow air turns right out of unit) R

Top Supply T

External

Static Pressure

0.5" 0

0.75" 4

B-7


1.0" 1

1.5" 5

2.0" 2

Other 3

Supply Air CFM

X

XY times 10 to the N Y

N

Space Heating

Type

Unit mounted electric Heater - Separate power connection D

Unit mounted electric heater - Single point power connection E

Unit mounted gas heating G

Remote by others N

Unit mounted steam coil S

Remote electric heater supplied by Seresco T

Unit mounted hot water coil W

Remote electric modulating heater supplied by Seresco X

Remote hot water coil supplied by Seresco Y

Remote steam coil supplied by Seresco Z

Heating Control

Details

Standard control signals: Valve and power supply by others 0

2 stages factory wired electric heating control 1

Modulating - factory supplied and wired valve 2

On/Off - factory supplied and wired Valve 3

Supply isolated 50 VA power for remote valve ( valve by others) 4

Modulating factory wired electric heating control 5

Supply On/Off Valve & 50 VA power for remote valve installation 6

Supply Modulating Valve & 50 VA power for remote valve installation 7

Unit Supply

Voltage

208/1 A

230-240/1 B

208/3 C

230-240/3 D

460-480/3 E

575-600/3 G

Unit Controls

Electro-mechanical 0

Command Touch Screen 1

Command Center 2

Command Center c/w Building Communication 3

Command Center c/w Remote Panel 4

Command Center c/w Building Communications & Remote Panel 5

Refrigerant

R410A A

R407C C

R22 R

Non fused Disconnect D

B-8


DisconnectFused Disconnect F

No Disconnect N

Warranties

Standard - 2yrs on driveline, coils, and compressor 0

2 yrs on driveline and compresor, 5 yrs on coils 1

2 yrs on driveline and compressor, 10 yrs on electrofined coils 2

2 yrs on driveline and coils, 5 years on compressor 3

2 yrs on driveline, 5 yrs on compressor and coils 4

2yrs on driveline, 5 yrs on compressor, 10 yrs on electrofined coils 5

2yrs on driveline and coils, 10 yrs on compressor 6

2yrs on driveline, 10 yrs on compressor, 5 years on coils 7

2yrs on driveline 10 yrs on compressor and electrofined coils 8

5yrs on driveline, 2 yrs on compressor and coils 9

5yrs on driveline and coils, 2 yrs on compressor A

5yrs on driveline, 2 yrs on compressor, 10 years on electrofined coils B

5yrs on driveline and compressor, 2 yrs on coils C

5yrs on driveline, compressor and coils D

5 yrs on driveline and compressor, 10 yrs on electrofined coils E

5 yrs on driveline, 10 years on compressor, 2 yrs on coils F

5 yrs on driveline and coils, 10 yrs on compressor G

5 yrs on driveline, 10 years on compressor and electrofined coils H

B-9


Unit Label

B-10


Further Information

For further information, please visit our website at www.serescodehumidifiers.com. Feel free to browse our

website and watch informative videos on every aspect of our products.

B-11

Issue Date : 2011-09-30 Section C - Pre-installation Requirements

Pre-installation Requirements

Seresco Technologies Inc. inspects and fully tests each dehumidifier in all operating modes before it ships from the factory.

The unit can suffer damage in transit. Check the equipment thoroughly for both visible and concealed damage before you

sign the receiving papers. Document any damage in writing on the carrier’s bill of lading to ensure that damage claims are

handled promptly. If the unit has been damaged, obtain a claim form from the carrier. Promptly fill out and return the form,

and notify Seresco Technologies Inc. of any damage.

Note : Damage claims or missing parts must be filed with the freight carrier.

Receiving Checklist

Note : The shipping protection provided by the factory is for transport purposes only and should not be

relied on to protect the unit in storage or on the job site.

Note : Seresco is not responsible for any shipping damages. Should your unit arrive damaged, please

follow the instructions in Shipping Damage Instructions to resolve the situation. Delivery cannot be refused

on the basis of shipping damages.

Upon receipt, please check the following components for damage:

Verify the proper operation of latches and hinges on all access doors

Inspect all coils for damage to the fin surface coating, headers or coil connections

Manually rotate the fan wheel to ensure free movement of the shaft, bearings and drive

Inspect the fan housings for any foreign objects

Inspect and test all piping for possible shipping damage

Check the tightness of bolts on the fan structure and coils

Inspect fan isolator shipping brackets

Shipping Damage Instructions

Seresco Technologies Inc. ships freight on board (FOB), meaning that the unit belongs to the customer as soon as the

delivery truck leaves the factory. If damage has occurred to the unit during shipment, follow these instructions:

1. Specifically note the extent of the damage in detail on the freight bill. Clear photographs of the damaged

C-1

Section C - Pre-installation Requirements Issue Date : 2011-09-30

components are required.

2. Report all claims of shipping damage to the delivering carrier immediately and coordinate a carrier

inspection if necessary.

3. Contact Seresco Technologies Inc. by email at [email protected] or by phone at (613)-741-

3603 and dial 2 for the soonest available tech support technician. Have the unit serial number (8-digit) and

nomenclature designation (23 digit alpha-numeric sequence starting with the series designation) on hand.

These may be found on the unit label along with other performance and electrical information.

4. Do not attempt to repair the unit without consulting the Seresco Technologies Inc. Service and Tech

Support Department. It is the receiver's responsibility to provide reasonable evidence that damage was not

incurred after delivery.

Storage

Protection from the elements is required for any unit that will be stored on the job site or a holding area before installation.

For long term storage, a controlled indoor environment is highly recommended. All factory-applied shipping protection

should be removed before the unit is put into storage. Shipping protection material is not suitable protection for short or

long-term storage.

Note : Standard Seresco warranties expire 24 months from the date of shipment.

See section Y – Warranties for further information.

C-2

Issue Date : 2011-09-30 Section D - Mechanical Installation

Mechanical Installation

WARNING Heavy objects ! Do not use cables (chains or slings) except as shown. Each of the

cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit.

Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for an even unit lift.

Other lifting arrangements may cause damage to equipment, serious injury or death of personnel. Always

place, assemble, and suspend single sections. Do not lift units in windy conditions. Do not raise units

overhead with personnel below unit.

WARNING Improper lifting procedure ! Test lift the unit 24 inches to verify proper operation of

lifting equipment and positioning of lift points such that the unit is level. Failure to properly lift the unit

could result in equipment damage, serious injury or death. Seresco Technologies Inc. is not responsible for

the improper use of lifting equipment.

WARNING When lifting unit, appropriate personal protection equipment (PPE) such as steel-

toed boots and hard hats must be worn to avoid potentially serious injury.

Lifting and Rigging Procedures

Determine the approximate centre of gravity before lifting the unit. Consult unit design drawings provided in

the submittal documents to determine total weight and weight distribution.

Never assemble split sections before lifting them to the installation location. Always lift sections as received

from the factory.

Lift sections using the provided lifting lugs

To avoid damage, do not attach intake or exhaust hoods prior to lifting the unit into place.

Unit Assembly (Split Units Only)

Under special conditions, the unit may be split into two or more sections to ease the installation process. Base angles are

attached using 3/8” bolts, and inside angles are bolted using 5/16” bolts. Ensure that all provided holes are used. Caulk

seams on the outside of the unit to make the join air-tight. Install the standing seam roof rib.

D-1

Section D - Mechanical Installation Issue Date : 2011-09-30

Duct Connections

All duct connections should be installed in accordance with local and national standards. To ensure the highest fan

efficiency, duct turns and transitions should be made to minimize air friction losses and turbulence. See supplied unit

drawing from the submittal for location and size of unit duct connections. Use only flexible duct connectors to connect to

the unit.

Piping and Unit Connections

See the unit label for unit connection line sizes. The installer must endeavour to ensure that all industry standards for

refrigeration component installation are met. This includes but is not limited to; proper line sizing, materials, nitrogen

purging, brazing with Silfos 5 or better (NO SOFT SOLDER), evacuation, cleanliness, traps, long radius elbows and system

charging.

Drain Pans - Condensate Drain

The dehumidifier is a draw through configuration as a result the entire cabinet is under negative pressure. Without a P-trap,

condensate will not drain and the unit will overflow into your mechanical room.

Per Figure 5 pitch the condensate drain line a minimum of 1/8” per linear foot, and support the pipe with code-

approved hangers at least every 5 feet.

If the drain line passes through an unconditioned space, heat tracing is required to prevent the condensate in the

drain from freezing.

When gravity disposal is not possible, a condensate pump can be used. Follow the pump manufacturer’s installation

instructions.

Figure D-1. P Trap

D-2


Blower Motor Brace

Upon installation remove ONLY lower bolt from all four corners shown in Figure D-2 (Detail A). The top of the bolt will

be spray-painted yellow for easy identification. The plug fan sits on spring dampers to minimize vibration translated to the

unit from the fan motor. During shipping, the fan assembly is fixed such that the springs are compressed and cannot

oscillate. Removing these bolts on installation ensures that the the fan vibrations will be dampened correctly.

Figure D-2. Blower Motor Brace

Figure D-3. Double motor assembly – remove horizontal brace on front wall

D-3


Field Installed Outdoor Air Cooled Condensers and Fluid Coolers

This condenser is used in air conditioning mode where it rejects unneeded heat from the space to outdoors. Proper

installation is essential to ensure it can function as intended. Proper airflow and refrigerant piping are paramount. Ensure an

appropriate maximum ambient air temperature has been specified. Ensure the unit has proper airflow per Figure D-4. A

perimeter of free area equal to its width must be provided. Use line sizes as specified by Seresco. To avoid potential seasonal

system charge problems, ensure the installed line lengths are never longer than indicated on the plans and specifications. If

the condenser is installed above the dehumidifier, ensure the hot gas line has proper oil traps. Contact Seresco if the

condenser is installed more than eight (8) feet below the dehumidifier. The installer must endeavour to ensure that all

industry standards for refrigeration component installation are met. This includes but is not limited to; proper line sizing,

materials, nitrogen purging, brazing with Silfos 5 or better (NO SOFT SOLDER), evacuation, cleanliness, traps, long radius

elbows and system charging. Install the remote condenser on a level, hard surface. Bolt the condenser in place.

Figure D-4. Typical Outdoor Condenser Installation

Refrigerant Piping of Remote Condensers

NE and NP series dehumidifiers are equipped with isolation valves and access valves located in the blower compartment. Do

not open the isolation valves until all exterior piping is leak checked and evacuated. The last outdoor condenser vacuum can

be broken with liquid refrigerant (R-407C or R-410A as applicable). Monitor the exact amount of refrigerant added, as the

total system charge must be per the unit nameplate. The NE and NP series dehumidifiers have refrigerant pipe stubs for the

line set connection inside the cabinet. Use standard commercial refrigeration piping practices when installing the

refrigeration piping between the dehumidifier and the remote air-cooled condenser.

Hot Gas and Liquid line sizes should be per unit nameplate. The stubs inside the unit will be the correct sizes

D-4


for line lengths up to 50’

Do not exceed 50’ total line length or install the condenser more than 8’ below the unit. Consult Seresco before

installing the outdoor air-cooled condenser more then 8 feet below or more than 50 feet away from the

dehumidifier.

Per Figure 2, install an oil trap at the start of and at every 15 feet of vertical lift in the hot gas discharge line as

shown. Pitch horizontal lines a minimum of 1/2” every 5 feet in the direction of flow. All piping must be clean

and de-burred. Keep copper chips and foreign materials out of the tubing. A nitrogen purge while brazing is

paramount to reduce the chances of oxidation in the pipes.

Keep the Hot Gas and Liquid lines a minimum of 2” apart to prevent heat transfer. Insulate the hot gas line in

all areas where a person may come in contact with the line and be in danger of a burn.

When all piping work is complete, check for leaks by pressurizing the remote condenser and line set with dry

nitrogen. If no leaks are detected, the circuit is ready to be evacuated. Evacuate the condenser and piping to a

minimum 250 microns. Isolate the piping for ONE HOUR to verify that the system is free from leaks, moisture,

and non-condensables. For further details on proper vacuum and evacuation procedures, see section H – Routine

Maintenance.

Figure D-5. Typical Outdoor Condenser Installation

D-5


Charging of Remote Condensers

Once a proper evacuation has been accomplished the system is ready for charging. The outdoor air-cooled condenser

requires a field charge by the installing contractor. The field charge required depends on the size of the condenser and the

length of the piping. The unit nameplate will show the exact field charge required. The last vacuum can be broken with

liquid refrigerant. Monitor the exact amount of refrigerant added, as the total system charge must be per the unit nameplate.

Connect the control wiring to the terminals provided inside the electrical compartment of the dehumidifier and outdoor

condenser. Refer to the low voltage wiring schematic for details. The condenser fan(s) will not operate until this is complete.

Once you have charged and checked the condenser and line set for leaks, open the service valves located in the compressor

compartment of the dehumidifier. There is an access valve in the liquid line after the pump down valve. The pump down

valve can be manually closed during start-up mode via the controller. Add only as much refrigerant as is needed to get to the

total charge indicated on the nameplate. Never charge liquid into the suction line access valve! The receiver has 2 sight

glasses with float balls to help ensure the maximum and minimum refrigerant levels are easily met.

Fluid Cooler Installation

Fluid cooled units come with a separate pump for the fluid loop. NP Series units have an internal pump and expansion tank

for the glycol loop. PVC piping is highly recommended for fluid cooler installation.

D-6


Factory Start-up Supervision

Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up

includes several key services:

The expertise of a factory-trained technician who will supervise the commissioning of the equipment.

This Seresco representative will assist the installing contractor with filling out the Start-Up Report.

They will also inspect the installation to make sure that the dehumidifier has been properly integrated with

the rest of the equipment on the job site.

Finally, they can train the maintenance personnel to operate and service the equipment if necessary.

A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring

that the system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco

reserves the right to bill the contractor for a second visit. When the installing contractor is confident the system

will be ready, contact the Seresco Sales representative to schedule the start-up. Please call at least two weeks

before the desired start-up date to prevent scheduling conflicts.

Items required for Start-Up

A service technician and a fully stocked service vehicle.

A set of refrigerant manifold gauges.

Air balancing equipment (magnehelic differential pressure gauge).

Volt/Amp/Ohm meters.

A digital thermometer w/clamp on sensors.

A halogen leak detector, R410a or R407c and a scale.

Items to be Completed Before Start-up

Refrigerant leak-check (with halogen leak detector) and inspect the unit for internal concealed damage.

Level and support the dehumidifier properly.

Install the outdoor air duct filters and damper (if applicable).

Install the condensate P- trap and drain lines and prime P-trap.

Pipe the remote condenser fan pressure controls to the condenser hot gas lines (if applicable).

Evacuate and leak-check the remote condenser line set (if applicable).

Tighten all electrical connections and verify that the line voltage is correct for the unit.

Install all controls and verify that all field wiring matches the schematic.

Fill and heat the pool and room to design conditions.

Install the pool water piping and a flow meter (if applicable). Purge all air from pool lines.

A complete system air balancing.

D-7



D-8

Issue Date : 2011-09-30 Section E - Electrical Installation

Electrical Installation

WARNING Disconnect all electric power, including remote disconnects, before servicing. Follow

proper lockout procedures to ensure that the unit is not accidentally powered. For variable frequency

drives, refer to the appropriate section of the manual. Verify with a voltmeter that all capacitors have

discharged. Failure to disconnect power and discharge capacitors before servicing could result in serious

injury or death.

Note : Use copper conductors only ! Unit terminals are not designed to accept other types of conductors.

Use of aluminium or other wiring may result in galvanic corrosion or overheating.

Note : Properly seal all penetrations made in the outer walls. Failure to due so may result in

unconditioned air entering the unit, water infiltrating the insulation or serious equipment damage. Ensure

that all metal shards and filings are swept to avoid possible corrosion or damage to electrical components.

Main Panel Power Connection

The field-installed power supply wires and over current devices must be sized to handle the minimum ampacity of the

dehumidifier without exceeding the maximum fuse size rating. Both the MCA and MOP are indicated on the unit

nameplate. Figure E-1 shows typical power wiring connections. Single-phase units require 3 wires, 2 power and one ground.

Three-phase units require 3 power wires and one ground wire. Connect the power supply wires to the main power

distribution block located inside the unit main electrical panel. For units with electric heaters and single-point power

connections, the power distribution block is located in the heater. For units with electric heaters and dual-point power

connections, the unit and heater must be powered independently. For units with mounted disconnects, ensure that the power

is brought first to the disconnect and then the power distribution block. Always verify the nameplate voltage before

connecting to the unit.

E-1

Section E - Electrical Installation Issue Date : 2011-09-30

Figure E-1. Main power distribution block

Control Wiring

Seresco Technologies Inc.'s dehumidifiers have all necessary sensors unit mounted and setpoints pre-programmed at the

factory. Remote duct heaters, outdoor air-cooled condensers, auxiliary pool water heaters and remote exhaust fans all require

interfacing with the dehumidifier. The common connection terminals are identified in Table E-1. For a complete list of

terminal connections and functions, refer to section Z – Annex.

Table E-1. Control Terminals

Pin I/O's Description

Connector J7

6 DI14 Freezestat

7 DI15 Firestat

Connector J8

7 AO01 Modulated Heat

Connector J9

1 , 2 DO24 Space Heater, Stage 2

3 , 4 DO23 Space Heater, Stage 1

5 , 6 DO22 Exhaust Fan 2

7 , 8 DO21 Exhaust Fan 1

9 , 10 DO20 Outdoor Air Damper

Connector J10

1 , 2 DI19 Outdoor Air Condenser 1

3 , 4 DI18 Outdoor Air Condenser 2 (Ver. 5.x only)

5 , 6 DI17 Auxiliary Pool Heater, Pool 2

7 , 8 DI16 Auxiliary Pool Heater, Pool 1

E-2


WebSentry Connection

Requires RJ45 ethernet connection to the unit.

To get access to WebSentry® you need to register a user id with Seresco. Follow these instructions.

1) Go to the Seresco web page at http://www.serescodehumidifiers.com.

2) Select the Login link in the upper right corner.

3) Select the ‘Click here to register’ link in the WebSentry® login box.

4) Fill in the registration form and submit it. The email address will be your user id.

Follow these instructions to login to WebSentry® and view your Seresco unit.

1) Go to the Seresco web page at http://www. serescodehumidifiers.com.

2) Select the Login link in the upper right corner.

3) Enter login credentials in the WebSentry® login box and click Submit button.

4) Once you have logged in you will see a list of all Seresco units you have access to. The very first time you login

the list is empty since you do not yet have permission to see any unit (see Gain Access to Unit).

5) Too see more detailed information for a unit, click the job name link.

6) The main Conditions page shows you the current conditions including a trend graph showing the room

temperature, humidity and optionally the pool water temperature over the past 4 hours.

You can also see current setpoints, logs and some basic unit configuration by selecting the appropriate menu link.

Gain Access to Unit

To gain access to a Seresco unit you need to know the serial number of the unit and the last 6 characters of the MAC

address. The latter is printed on a bar code label on the control board where the network cable is plugged in. You can also

find this information from the System Info page from the key pad (accessible from User Settings). If you are not able to get

to this information you can also contact Seresco and someone will be able to help you get access to the unit.

Controlling Unit

To gain control of unit so that you can change setpoint, restart unit or modify some factory settings, you first have to

Connect to unit and have it maintain a live connection. By default the unit connects once a minute to upload latest sensors

readings and log entries and then disconnects again. Typically this does not take more than one second.

To get a live connection, click the Connect button on any page that has a Connect button. Keep pressing Connect button or

Web browser refresh button until Connect button changes to a Save and Refresh button.

E-3


Another indication that unit is live is that the time stamp in the header under the job name changes to Live. Normally the

time stamp tells you the last time the unit connected to the WebSentry® server.

Once a live connection has been established you can change any unit parameter like setpoints and factory settings. From the

conditions page you can also start and stop the main blower and restart the unit. If unit is equipped with a purge feature, you

can also initiate purge from the conditions page.

Remote Operator Panel (ROP)

The Remote Operator Panel (ROP) looks identical to the local keypad but instead of being connected to the main control

board using a data ribbon cable, it uses a RS-485 serial port communication interface. Cat3 or Cat5 twisted pair cables must

be used between the ROP and the main CommandCenter control board.

The other difference between the local keypad and the ROP is that the ROP has its own processor and memory where the

menu system is stored opposed to the local keypad which just a “dumb” terminal displaying the menu system as controlled

by the main control board.

When installing or replacing the ROP you can run into several issues that will prevent the ROP from working properly. This

document covers all steps you need to take to ensure a good communication between ROP and main control board.

Testing Remote Operator Panel at the unit

To rule out any type of problem with the wiring between the unit and the ROP location, use a 3’-5’ wire and connect the

ROP to the main board right at the unit. All troubleshooting guides in this document applies to both testing ROP at the unit

and at its final location.

NOTE! When doing any rewiring like moving wires from J8 to JCOM or moving ROP between final location and testing it

at the unit, make sure the dip switches are in the off position (towards the 1 & 2 label on the dip switch socket). Do not move

to on position until powered up and red LED (L1) is lit up.

Using proper cable

We recommend using a twisted pair Cat3 or Cat5 cable. What is important is that the two signal wires are twisted together.

Twisting the signal wires together acts as a noise filter. If not using this type of cable you can run into communication issues.

E-4


Especially if the ROP is far away from the unit. For easier troubleshooting, use the following coloured wires.

Table E-2. ROP Connections

Cat3/Cat5 Wire Remote Keypad J8 JCOM

Orange J8-1 (+24V) Pin 1 Pin 5

White/Orange J8-2 (GND) Pin 2 Pin 4

Blue J8-5 (+ 485) Pin 5 Pin 6

White/Blue J8-6 (- 485) Pin 6 Pin 7

Connecting wires

Before doing any wiring, ensure there is no power over the wires. Either power unit off or unplug terminal (J8 or JCOM) to

where the ROP is connected. Connect wires to main control board terminal as listed in Table 1. By default you should be

using terminal J8. JCOM is only used as a backup RS-485 port or when more than one RS-485 port is needed. Open up the

back of the ROP and feed wires through the hole of the back plate and connect wires to terminals as listed in Table E-2.

Check communication

Power up unit or plug in terminal block again. If the two power wires are wired correctly you should now see the red L1

LED light lit up in the ROP. If there is power you can now safely activate the signal wires. You do this by moving the two

dip switches (SW1) next to the green terminal block towards the top of the ROP. This is easiest done by using a small flat

head screw driver.

If signal wires are wired up correctly you should see the main sensor screen within a few seconds (possibly the system

startup screen).

If the screen is blank, you see the Welcome screen for more than 10 seconds, or see other messages indicating the ROP is

trying to establish communication, continue reading this document to help you troubleshoot the problem.

No power to ROP (LED L1 not lit up)

First make sure unit is powered up and that the terminal block (J8 or JCOM) is plugged into the main control board.

Make sure wires are wired as listed in Table 1. Make sure that the terminal in the ROP is grabbing onto the copper and not

the insulation. Check this at the main control board as well. There could possible be a kink in the cable causing a broken

wire. Test ROP at unit using a short cable. Try both J8 and JCOM in case there still is no power connecting to J8. If still no

power you most likely have a failed ROP terminal board.

E-5


Power to ROP but showing a blank screen

There should never be a blank screen when there is power to the ROP. At the minimum the ROP should show that it is trying

to connect to the main control board. There are only two reasons why there is a blank screen. The ROP has a contrast dial. It

might have been moved so that there is no contrast at all resulting in a blank screen. The contrast dial is a white dial in the

upper left corner next to the terminal board. Use a small screw driver to adjust it. If you see no change at all on the screen

when adjusting the dial, then this is not the problem. The second reason for a blank screen is if the menu program has been

erased from memory. A static chock could possible cause this. All ROP’s are tested at the factory so there should have been a

program installed when the ROP was shipped from factory. Once again, to really rule out a wiring issue, test the ROP using

a short cable right at the unit.

Power to ROP but not establishing a connection

First thing to check is that the two dip switches has been moved up to activate the signal wires. Make sure wires are wired as

listed in Table E-1. Make sure that the terminal in the ROP is grabbing onto the copper and not the insulation. Check this at

the main control board as well. There could possible be a kink in the cable causing a broken wire. Test ROP at unit using a

short cable. Try both J8 and JCOM in case there still is no communication when wired to J8. If still no communication, read

the next section to do one more last test.

Check for communication attempt

From the main control board you are able to look at data streams for anyone of the 3 serial ports. We can use this to

determine if the ROP at least is getting some message through to the main control board. Start up the unit in Service Mode.

Go to the Main Menu (1) and then Service (6) – Network (3) – Console (2). Use arrow keys to select port. Port D is RS-485

on J8 and Port C is RS-485 on JCOM. Select 1 to start serial port monitor console. If there is communication you should see

a bunch of characters within a few seconds. You should also see them changing every few seconds. Stop by pressing 2 or the

Back key. If there is no character stream them most likely the RS-485 communication chip on either the ROP or the main

controller board has failed. There is no way to check which one so if you do not have a second ROP a second board to test

with, there is no way to know. With our newer boards (4.1 and later) we have two RS-485 ports as discussed in this

document so the chances that both communication chips have failed are very small. For these boards we will replace the

ROP with a new one. For older units using a 3.1 board or older, there was only one RS-485 port so for these units we have to

replace both the main controller board and the ROP.

If there is a character stream but still no communication at the ROP, check the serial port communication settings to make

sure they have not been changed. See next section. Check serial port configuration settings. From the Main Menu, go to

E-6


Factory Settings (5) – Network (5) – Serial Ports (2). Then select either Port C (JCOM) or Port D (J8) depending on which

terminal you are testing. User should be set to Seresco, Baud Rate to 57600, Databits to 8, Parity to None. The timer Reply

Delay should be at least 500 but new recommendation is 750. The timer Invalid Data should be set to 1000.

Echo Test is by default set to Yes but you can try setting this to No to see if this will establish a connection. By default a RS-

485 is echoing back every sent message back to the sender. Our controller is using this to test for a robust connection. We

have however seen cases where the RS-485 communication chip partially has failed where it no longer echoes back sent

messages but otherwise functions just fine. By setting the Echo Test to No we can test for this fault.

If you did any configuration change but still no communication you can try doing a System Restart to see if it this will help.

Either power off unit in between or unplug ROP terminal from board to cycle the ROP. If you still are not being able to

establish communication after doing these steps, we have an unknown fault and the ROP needs to be replaced. If this already

is a new ROP, we need to replace the board.

ROP shows Version Mismatch

If the ROP display show Version Mismatch it means you are connecting a ROP to a unit running a software version with

which the ROP is not compatible. Get a new ROP with a version compatible with the software version on the unit.

E-7



E-8

Issue Date : 2011-09-30 Section F - Startup

Start-Up

WARNING Disconnect all electric power, including remote disconnects and discharge all motor

start/run capacitors before servicing. Follow proper lockout procedures to endure the unit cannot

accidentally be powered. For variable frequency drives or other energy storing components, refer to the

appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with

a voltmeter that all capacitors have discharged. Failure to disconnect power and discharge capacitors

before servicing could result in serious injury or death.

WARNING Rotating components ! During installation, testing, servicing and troubleshooting of

this product it may be necessary to measure the speed of rotating components. Have a qualified or licensed

service individual who has been properly trained in handling exposed rotating components perform these

tasks. Failure to follow all safety precautions when exposed to rotating components could result in serious

injury or death.

WARNING Live electrical components ! During installation, servicing and troubleshooting of

this product, it may be necessary to work with live electrical components. Have a licensed electrician or

other qualified individual perform these tasks. Failure to follow all electrical safety precautions when

exposed to live electrical components could result in serious injury or death.

Pre-Startup Checklist

A complete start-up is required to ensure that all systems have been configured to ensure optimal and reliable unit operation.

Final adjustments should be made when all space and water temperatures are at design conditions. The use of auxiliary or

portable air heaters may be required to heat the room. Read this section thoroughly before attempting to commission the

Seresco Technologies Inc. dehumidifier. Ensure that the unit installation conforms to all recommendations made by Seresco

Technologies Inc. in this manual. Complete the pre start-up section of the warranty registration / start-up form provided in

section Z – Annex.

Note : Do not use the unit as a construction site heater. Construction material will infiltrate the unit and

can significantly deteriorate unit performance and lifespan.

F-1

Section F - Startup Issue Date : 2011-09-30

General Checks

Ensure that the unit has been installed on a level location

Check to ensure all packing materials and shipping brackets have been removed from the unit

Verify that any remote space heating coil is installed in the supply air duct (after the unit) and not in the

return air duct (before the unit)

Ensure supply and return air ducts have been connected

Verify damper operation and alignment, as damper blade position may change in shipment

Check that air filters are clean, in place and positioned properly

Remove any debris from the unit interior

Close and secure all unit access door in the airstream

Inspect electrical connections to the unit and unit controllers

Connections should be clean and secure

Compare the actual wiring with provided wiring diagrams

Reference the controls section of this manual for more details on factory mounted controls

Leave this manual with the unit

Fan/Motor-Related Checks

Ensure that fan assembly braces have been removed

Rotate all fan wheels manually to confirm they turn freely in the proper direction

Inspect fan motor and bearings for proper lubrication

Coil-Related Checks

Ensure coil and condensate drain piping connections are complete

Check the piping and valves for leaks. Open and close the valves to check operation

Remove all foreign material from the drain pan

Test the drainage and prime the P-trap by pouring water into the drain pan

Note : For units with water cooled air conditioning. The use of untreated or improperly treated water in

coils may result in scaling, corrosion, erosion, algae or slime. It is recommended that the services of a

qualified water treatment specialist be engaged to determine what water treatment, if any, is required.

F-2


Electrical Checks

Check nameplate for power requirements and confirm that it matches the available power supply

Voltage must be within ±10% of nameplate voltage. Verify that all field wiring matches provided wiring

schematics. Inspect and tighten all field and factory wiring

Leave power on and allow 24 hours of crankcase heater operation before attempting start-up.

Ensure that the control wiring has been installed to the outdoor condenser / cooler if applicable

Ensure all peripheral controls and sensors are connected and wired correctly

Pool Water Checks

For units with pool water heaters only. Energize the circulating pump and establish water flow. Inspect the

piping and repair any water leaks. Ensure that control wiring has been installed between the unit and the

auxiliary pool water heater

Refrigerant Line Checks

Verify that all service valves in the refrigeration lines are open

Leak test (with halogen leak detector) all factory and field piping. Shipping and handling may have caused

refrigerant leaks inside the dehumidifier

Start-up Procedure

All appropriate fields and sections of the warranty registration / start-up form should be completed. A proper start-up

requires that the unit be run and monitored in all modes of operation at design conditions with the operating data recorded

on the forms provided in section Z – Annex. Seresco's service technicians review every report to ensure all aspects of the

system are functioning within normal operating parameters. Carefully follow the process detailed in the start-up report. If

the space is not at design conditions at the time of start-up, a follow-up visit for final adjustment and balancing is required.

Mail or fax the completed warranty registration / start-up form back to Seresco to validate your unit's warranty See section

Y – Warranty for further information. If you do not have a start-up report, call Seresco for a new copy or download a PDF

version from www.serescodehumidifiers.com.

F-3


Note : Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up

Report” is completed and sent to the factory within one week of initial start-up. This report will also

register the compressor warranty with the compressor manufacturer.

Power Turned ON (or after power failure)

When powered, the blower begins to operate immediately and will do so continuously. The microprocessor initiates a self-

test and runs systems diagnostics algorithms. If all systems check out, the microprocessor used sensor feedback to resume

normal unit operation. The microprocessor will confirm that the compressor has been off for at least five minutes using its

internal clock.

The CommandCenter keypad display should show current sensor readings and the main menu. For keypad layout and

function refer to section G – Nx Series Unit Operation, under CommandCenter operation.

Check time and set-points by doing the following:

Current Time: 1-Main Menu, 4-User Settings, 2-Date&Time

Set-points: 1-Main Menu, 1-Setpoints

Check remote operator panel response, if applicable, and record all data on the start-up forms.

Check Component Operation

To force component operation, do the following:

1-Main Menu, 6-Service, 2-Forced Contacts

To activate, switch component status from OFF/No to ON/Yes, to switch off do the reverse

Ventilation components (under 2-Ventilation) to check include (as applicable) the main blower, condenser fan(s), damper(s),

exhaust fan(s) and purge fan(s) (also known as exhaust 2). Ensure proper, uninhibited rotation of the fans, check and record

amperage readings on the start-up forms.

For heating components (3-Heating), first check whether the space heating option is staged or modulating. To activate

modulated heating, select the modulated option, then use the up and down arrows followed by Enter to select the desired

F-4


heating load. To activate Staged heating, enable stage 1 (and stage 2 if applicable).

Note : for units equipped with a gas water boiler and modulated valve, activate stage 1 first to start the

circulating pump(s), then activate modulated heating as described above.

CAUTION Ensure that the main blower is on while testing the heating system or compressor.

Enabling the Compressor(s)

Compressors are disabled after testing at the factory to prevent their accidental non-supervised start-up. To start the

compressor(s):

1-Main Menu, 5-Factory Settings, 4-Compressor, 1-Enabled and switch to Yes to enable the compressor

Ensure that design conditions (return air temperature and relative humidity) are established, the main blower is running, and

a gauge set is attached to verify compressor rotation and performance. Make sure that gauge readings correspond to unit

pressure sensor readings shown on the keypad.

Forced Modes

Check unit condition under different modes of operation by doing the following:

Set forced demands: 1-Main Menu, 6-Service, 1-Forced Demands, 1-Compressor 1

To run the unit in dehumidification mode, choose Dehumidify and check pressure, temperature readings. Allow the

compressor to run for 20-30 minutes and ensure that the superheat is within 19-22°F, making adjustments if required. Record

all data.

To run the unit in dehumidification and pool heat modes, select Pool Heat while the compressor is still running. Make sure

that design water flow is provided to the unit. Record actual water flow GPM and pressure.

Confirm and record superheat data. Deselect dehumidification and pool heat modes by selecting OFF/No and allow the

F-5


compressor to pump down.

To run the unit in air conditioning mode, select 2-A/C, then air conditioning and pool heat modes. Follow procedure

outline above, recording all data on the start-up forms.

For units with two or more compressors, complete the process for each compressor individually, and finally both together.

To restart the unit in normal mode, do the following:

1-Main Menu, 6-Service, 6-Commission, 2-Commissioned and switch to ON/Yes

1-Main Menu, 3-System, 3-System Restart, 1-Yes

After the system shuts down and restarts, select Normal Mode

Submit the completed start-up report by Fax: 1-613-741-3375 or e-mail: [email protected].

Factory Start-up Supervision

Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up includes

several key services:

The expertise of a factory-trained technician who will supervise the commissioning of the equipment.

This Seresco representative will assist the installing contractor with filling out the Start-Up Report.

They will also inspect the installation to make sure that the dehumidifier has been properly integrated with

the rest of the equipment on the job site.

Finally, they can train the maintenance personnel to operate and service the equipment if necessary.

A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring that the

system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco reserves the right to

bill the contractor for a second visit. When the installing contractor is confident the system will be ready, contact the Seresco

Sales representative to schedule the start-up. Please call at least two weeks before the desired start-up date to prevent

scheduling conflicts.

F-6


Items required for Start-Up

A service technician and a fully stocked service vehicle.

A set of refrigerant manifold gauges.

Air balancing equipment (magnehelic differential pressure gauge).

Volt/Amp/Ohm meters.

A digital thermometer w/clamp on sensors.

A halogen leak detector, R410a or R407c and a scale.

Items to be Completed Before Start-up

Refrigerant leak-check (with halogen leak detector) and inspect the unit for internal concealed damage.

Level and support the dehumidifier properly.

Install the outdoor air duct filters and damper (if applicable).

Install the condensate P- trap and drain lines and prime P-trap.

Pipe the remote condenser fan pressure controls to the condenser hot gas lines (if applicable).

Evacuate and leak-check the remote condenser line set (if applicable).

Tighten all electrical connections and verify that the line voltage is correct for the unit.

Install all controls and verify that all field wiring matches the schematic.

Fill and heat the pool and room to design conditions.

Install the pool water piping and a flow meter (if applicable). Purge all air from pool lines.

A complete system air balancing.

F-7



F-8

Issue Date : 2011-09-30 Section G - NP Series Unit Operation

NP Series Unit Operation

Sequence of Operation

The standard sequence of operation for a Seresco dehumidifier is relatively simple. Whenever the compressor operates, the

evaporator is always dehumidifying and cooling the return air. The heat removed from the air at the evaporator, as well as

the heat from the compressor's action, must be rejected to one of three heat sinks; room air, pool water (if applicable) or

outdoors. The microprocessor will direct the heat to where it is needed based on room conditions.

Dehumidification Mode

Dehumidification Mode occurs when the space requires dehumidification. The air discharged from the unit is drier and

approximately 20°F warmer than when it entered. This mode engages when the return air relative humidity is above the set-

point. The hot gas is condensed in the reheat coil, returning heat to the room air.

Air Conditioning Mode

Air Conditioning Mode occurs when the room air requires only cooling, all of the refrigerant hot gas is directed outdoors,

either directly (outdoor air cooled condenser, etc) or indirectly (water cooled, outdoor air fluid cooler, etc). The air

discharged from the unit has been dehumidified and is about 15°F cooler than when it entered. In stage one air

conditioning, the compressor starts (if not already operating in dehumidification mode), the evaporator sees nominal air

flow, and the hot gas condenses at the outdoor air cooled condenser or equivalent. In stage two air conditioning, the system

performs as in stage one air conditioning, except the evaporator bypass damper closes to maximize air moving across the

evaporator coil.

Pool Heating Mode

If the unit is in dehumidification or air conditioning mode, there is free heat available in the system to heat the pool water.

This pool water heating mode engages if the pool water drops below the set-point. Water heating alone will not start the

compressor, thus there must be a pre-existing demand for this mode to operate. When in pool water heating mode, the pool

water control valve directs hot refrigerant through the coaxial heat exchangers. This system also acts as a refrigerant

subcooler, increasing system efficiency and capacity. If there is no other demand for the compressor to operate, the

microprocessor sends a signal to the external auxiliary pool water heater (provided by others). No additional controls are

required to operate the auxiliary water heater.

G-1

Section G - NP Series Unit Operation Issue Date : 2011-09-30

Continuous Blower Operation

Units have been factory wired for continuous blower operation. This helps prevent air stratification and stagnation. This is

also required to ensure that the sensors produce accurate data.

Compressor Start Sequence

All Seresco NE/NP Series units have a pump down sequence and anti-short cycle timer. When a demand requires the

compressor to operate, the following sequence occurs: blower operation is confirmed by the microprocessor and anti short

cycling timer (ASCT) sequence completes, the pump down solenoid valve opens, the low pressure safety switch will activates

at 25psig, and the compressor starts.

Space Heating Option

The microprocessor control is designed to control a space-heating coil mounted locally or remotely. When the room

temperature drops below the set point, the microprocessor will send a signal to start the heating coil.

Purge

Used for complete air changeover in pool environment after super-chlorination. Return air damper is completely closed,

resulting in all air from the pool space being exhausted, while fresh air is brought in from the outdoors. Also used for

economizer cooling when conditions warrant.

Heat Recovery

The energy a room loses from the exhaust air, as a result of the fresh air requirements, can represent up to 50 % of the

room's heating requirements. Approximately 50-60 % of this exhaust heat can be recaptured with a heat recovery loop. By

doing so it supplies heat to warm the cold outside air and can provide generous energy savings to the room to reduce heating

costs. During freezing weather conditions the outdoor air can provide much of the dehumidification required, and

minimizing the time the compressors run offsetting some of the running electrical costs.

Our typical energy recovery loop consists of two glycol coils: one in the outside air intake and the other in the exhaust air-

stream. The coils are connected in counter-flow closed loop piping system. The system comprises an inline fluid cooled

pump, an air separator, and in some larger systems a pressure tank and pressure gauge. By circulating a glycol mixture,

G-2

Issue Date : 2011-09-30 Section G - NP Series Unit Operation

typically 30%, we can extract enough heat from exhaust air stream to preheat the outside air intake to about 50-60% of the

room temperature. Extracting more heat from the exhaust air stream is possible but would also lead to possibly freezing of

the exhaust air and would require a more complex and costly system of frost prevention. Keeping our effectiveness down to

50-60% reduces initial cost and keeps things simple.

Figure G-1. Heat recovery loop

Types of Solutions

We recommend and typically use ethylene glycol in our systems but local codes or building requirements may specify

propylene glycol mixtures. The higher viscosity of propylene means a stronger pump is required or a lower circulating water

flow will occur. So it is best to contact the factory if a switch from one glycol to another is preferred. It is important to use

corrosion inhibitors and in the correct amount. When adding the corrosion inhibitor solution please followed the suggested

instructions for the required quantity of fluid. Seresco strongly recommends that the glycol, if not already mixed, be mixed

with distilled water. Topping up and pressurizing the system can be done with clean tap water. In municipalities where local

tap water has a high mineral content, Seresco strongly advises the use of distilled water to prevent “sludging” and premature

failure.

Annual testing should be made of the fluid solution to ensure the adequate glycol concentrations and corrosion inhibitor

protection. Freeze point and PH test strips are available from your local plumbing supply house. It is important to ensure the

solution will not freeze in the case of a power failure or that it is not acidic and will corrode the system. The glycol mix

should be replaced after 5 years or when quality is deem unsatisfactory and cannot be restored.

G-3

Section G - NP Series Unit Operation Issue Date : 2011-09-30

Filling or Refilling the Glycol Loop

When filling the system please insure all air has been removed. Air in the system will cause corrosion and improper

functioning of the pump. Do not run the pump for any extent time with air in the system it will foam up the glycol and this

will make it difficult to remove the air. If this happens pressurize the system with some water to about 15 PSI and let stand

overnight. Before restarting vent as much air as possible running the pump for very short burst to move the water and any

possible air bubbles around slowly to the vents. For systems with a pressure tank keep the system under a 10-15 PSI positive

pressure to ensure no air get into the system. If the system is left dry for any period of time electrically disable the pump to

avoid it possible coming on without fluid in the system. Please keep record, near the unit, the type of glycol used; ethylene or

propylene, the two types should not be mixed. Keep careful track of what percentage by volume was used and when it was

changed. And the last time it was checked.

G-4

Issue Date : 2011-09-30 Section G - NP Series CommandCenter Operation

CommandCenter Operator Panel – Software Version 5.3.2

Introduction

This document describes the different features of the Operator Panel (installed locally or remotely) that is used with the NP

Series of dehumidification units.

Startup Screens

When the unit start up you will see the following menu screen. A 60 second timer is started and if no selection is made

before timer expires, Normal Mode will automatically be selected.

1. Normal Mode

2. Service Mode

Selecting Normal Mode will take you to the main sensor screen. If the voltage monitor fault signal is not active, blower will

start right away. If voltage monitor fault signal is active, 60 second timer will continue running. When timer expires, the

voltage monitor fault signal will be checked again. If signal now is cleared, the blower will start, otherwise blower will

remain off and there will be a voltage monitor fault alarm.

Navigation Mode and Edit Mode

The menu system implements two different modes where the keys have different meanings. Navigation mode is used to

navigate the menu system and Edit mode is used when changing data.

The following keys are used in Navigation mode:

Keys 1-3 (and 4-6) are used to select a menu item. If there are more than 6 menu items, menu items will be

listed 1-3 on every screen.

Up and Down arrows are used to scroll up or down a page. Arrows at the top right corner indicates which

direction you can scroll. If no more than 6 items either down or up arrow will be displayed (no scrolling

“around corner”). If more than 6 menu items, both arrows will be displayed and you can scroll “around the

corner”. Obviously no arrows when 3 or less menu items.

Back key takes you back to previous menu level.

G-6

Section G - NP Series CommandCenter Operation Issue Date : 2011-09-30

Enter key has a special meaning. From any menu screen it will take you directly back to the main screen (the

sensor screen). If you now press the Back key it will take you back to the screen where you were before pressing

Enter. On the sensor screen you can still use the Up and Down arrows to scroll up and down a page and the

Back key will still take you back to where you were before pressing Enter. If you press 1 however (Main Menu)

the back shortcut is lost (it’s not a true history list yet).

Key 3 on the sensor screen is another hidden feature. It will toggle sensor readings between displaying values

with a one decimal prevision and no precision. Default is no precision. This applies to all temperatures and the

humidity level.

To enter Edit mode you select the number key corresponding to the data item you want to edit on a navigation screen with

data items. To indicate that you are in edit mode, the data value is highlighted.

The following keys are used in Edit mode:

Keys 1-3 are not used.

Up and Down arrows are used to scroll up and down in the value list. More info about different types of data

items later in this document.

Back key takes you back to navigation mode and cancel any changed data. Data is with other words not saved

when you press the Back key.

Enter key will save the data and most of the time take you directly back to navigation mode (covered under data

types).

Data Types

Most of the data (properties) you can change are changed using values in a selection list. You use the Up and Down arrows

to scroll up and down in the selection list. You can scroll “around the corner”. For data items with only two selection items

(e.g. Yes/No), you can use either the up or down key to toggle between the two values.

Most Integer values are edited as lists with a min and max range. The value might also be restricted to be changed in specific

increments (e.g. 5, 10, 15, 20, …). In a few rare cases integer values are entered one digit a time. When entering edit mode,

the integer value will be displayed as a five digit zero padded number. To enter a number less than 5 digits, leave the first

digits at 0. Press Enter until all digits are set.

Date and Time values are edited in a special way. Using date as an example, when entering edit mode, the year (or last two

digits of the year) will be highlighted. Use Up and Down arrows to change year. When done, press Enter. Now the month

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will be highlighted and you change it in the same way. Press Enter again and the day is highlighted. Pressing Enter a final

time will save the new date. Pressing Back at any time when editing the date will cancel the change operation and take you

back to navigation mode.

A time value is entered in the same way as a date. An IP address is entered the same way as date and time except that you

edit one digit at a time. Passwords are entered one digit at a time pressing Enter after each digit.

Information Messages

Certain actions and certain conditions will generate information messages. Information messages will popup over current

menu screen. The message can be cleared by pressing either key 1 or 2. Key 1 will clear current message and key 2 will clear

all queued messages. Messages can be of three different types. Short, Long or Confirmed. A short message will be cleared

automatically after 3 seconds (default). A long message will be cleared after 5 minutes (default). A confirmed message will

never be cleared (unless there is a system restart) and have to be cleared by pressing key 1 or 2.

Menu Structure Quick Reference

The root menu screen is where you see all the sensors and one menu option that takes you to the Main Menu. Some menu

selections are dependent on current unit configuration and will not always be displayed. These menu selections are marked

as Optional. For data menu items, the default value is displayed in the summary.

1. User Settings

1.1. Setpoints

1.1.1. Temperature

1.1.2. Humidity

1.1.3. Pool Temp

1.1.4. Pool 2 Temp

1.1.5. Freezestat

1.1.6. Purge Temp

1.1.7. Economizer

1.1.8. Disable A/C

1.1.9. Heat Recovery

1.2. Date & Time

1.2.1. Date

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1.2.2. Time

1.2.3. Zone

1.2.4. Date Format

1.2.5. Time Format

1.3. System Info

1.4. Occupied Schedule

1.4.1. Empty

1.4.1.1. Day(s)

1.4.1.2. On

1.4.1.3. Off

* 1.3.2 – 1.3.3 same as 1.3.1

1.5. Filter Schedule

1.5.1. Date

1.5.2. Interval

1.6. Display

1.6.1. Backlight

1.6.2. Temp Unit

1.6.3. Reset Display

1.7. User Password

1.7.1. Enabled

1.7.2. Password

1.7.3. Retention

1.8. Remote OP * Only visible on Remote OP

1.8.1. Version Info

1.8.2. Port Configuration

2. Alarms

2.1. Current Alarms

2.2. Alarm Log

3. System Control

3.1. Start/Stop Blower

3.2. System Restart

3.3. System Status

3.3.1. Environment

3.3.2. Compressor

3.3.3. Ventilation

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3.3.4. Network

3.3.5. Serial Ports

3.3.6. Control Status

3.4. Purge

4. Factory Settings

4.1. Ventilation

4.1.1. Options

4.1.1.1. Purging

4.1.1.2. Economizer

4.1.1.3. Eco Offset OA

4.1.1.4. Eco Offset DP

4.1.1.5. Fire Reset

4.1.2. Blower

4.1.2.1. Normal Speed

4.1.2.2. Max Speed

4.1.3. Timers

4.1.3.1. Stabilize

4.1.3.2. Freezestat 1

4.1.3.3. Freezestat 2

4.1.3.4. No Airflow

4.1.3.5. Purge Time

4.1.3.6. Dirt Filt Dly

4.2. Compressors

4.2.1. Configuration

4.2.1.1. Compressor 1

4.2.1.1.1. Available

4.2.1.1.2. Resource ID

4.2.1.2. Compressor 2

4.2.1.2.1. Available

4.2.1.2.2. Resource ID

4.2.2. Options

4.2.2.1. Enabled

4.2.2.2. Design

4.2.2.3. Refrigerant

4.2.2.4. OACC Type

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4.2.2.5. Emergency Heat

4.2.2.6. Superheat

4.2.2.7. Reheat Steps

4.2.2.8. Reheat Time

4.2.2.9. Reheat Calib

4.2.2.10. BPD Steps

4.2.2.11. BPD Turn Time

4.2.2.12. BPD Stabilize

4.2.2.13. Partial Mode

4.2.2.14. Partial Transit

4.2.2.15. PD At Start

4.2.2.16. PSI Monitor

4.2.3. Timers

4.2.3.1. Min Startup

4.2.3.2. Stabilize

4.2.3.3. Min Run Time

4.2.3.4. Min Stop Time

4.2.3.5. Alarm Stop

4.2.3.6. Anti Block

4.2.3.7. Superheat Dly

4.2.3.8. SucTemp Dly

4.2.3.9. Oil Fault

4.2.4. Pressures

4.2.4.1. LP Vacuum

4.2.4.2. LP Alarm

4.2.4.3. LP Start

4.2.4.4. LP Normal

4.2.4.5. LP Deadband

4.2.4.6. LP Max

4.2.4.7. HP Min

4.2.4.8. HP Alarm

4.2.4.9. HP Relief

4.2.4.10. HP OACC Min

4.2.4.11. HP OACC Max

4.2.4.12. OACC HP Change

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4.2.4.13. OACC Deadband

4.3. Space Control

4.3.1. Room Temperature

4.3.1.1. Deg*Min On

4.3.1.2. Deg*Min Off

4.3.1.3. Setpoint Adj

4.3.2. A/C

4.3.2.1. Operation

4.3.2.2. Deg*Min On


4.3.2.4. Sensor

4.3.3. Heating

4.3.3.1. Type

4.3.3.2. Deg*Min On


4.3.3.4. Sensor

4.3.3.5. Mod Step Size

4.3.3.6. Stage 2 On

4.3.4. Humidity

4.3.4.1. Deg*Min On


4.3.4.3. Temp Offset

4.3.4.4. High Humidity

4.3.5. Deadbands

4.3.5.1. Air Temp Low

4.3.5.2. Air Temp High

4.3.5.3. Humidity Low

4.3.5.4. Humidity High

4.3.5.5. Heat Rec High

4.3.5.6. SA Temp Low

4.3.5.7. SA Temp High

4.4. Pool Control

4.4.1. Pool 1

4.4.2. Pool 2

4.4.3. Contact 2

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4.4.4. 100% Heating

4.4.5. Heat Sink

4.4.6. Min Out Temp

4.4.7. High Flow Dly

4.4.8. HP Pool Fault

4.4.9. HP Relief

4.4.10. Waterflow Rec

4.4.11. Max Trips Time

4.5. Network

4.5.1. TCP/IP

4.5.1.1. DHCP

4.5.1.2. IP

4.5.1.3. Mask

4.5.1.4. GW

4.5.1.5. DNS

4.5.1.6. Link Monitor

4.5.1.7. Start Device

4.5.1.8. Reboot Device

4.5.1.9. Reboot Delay

4.5.2. Serial Ports

4.5.2.1. Port B (RS-232)

4.5.2.1.1. User

4.5.2.1.2. Baud Rate

4.5.2.1.3. Databits

4.5.2.1.4. Parity

4.5.2.1.5. Flow Control

4.5.2.1.6. Reply Delay

4.5.2.2. Port C (RS-485)

4.5.2.2.1. User


4.5.2.2.3. Databits

4.5.2.2.4. Parity

4.5.2.2.5. Echo Test

4.5.2.3. Port D (RS-485)

4.5.2.3.1. User

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4.5.2.3.3. Databits

4.5.2.3.4. Parity

4.5.2.3.5. Echo Test

4.5.3. WebSentry

4.5.3.1. Enabled

4.5.3.2. Use DNS

4.5.3.3. IP

4.5.3.4. Port

4.5.3.5. Comm Interval

4.5.3.6. Comm Segment

4.5.3.7. Stay Alive

4.5.4. BACnet [Optional]

4.5.4.1. Enabled

4.5.4.2. Interface

4.5.4.3. Device ID

4.5.4.4. Port

4.5.4.5. Heartbeat

4.5.5. Modbus [Optional]

4.5.5.1. Device ID

4.5.6. LON [Optional]

4.5.6.1. Enabled

4.5.6.2. Interface

4.5.6.3. Refresh Rate

4.6. Inputs/Outputs

4.6.1. Sensor Type

4.6.1.1. HP

4.6.1.2. LP

4.6.1.3. Superheat

4.6.1.4. HP 2

4.6.1.5. LP 2

4.6.1.6. Superheat 2

4.6.1.7. Return Air

4.6.1.8. RA Humidity

4.6.1.9. Outdoor Air

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4.6.1.10. OA Humidity

4.6.2. Sensor Usage

4.6.2.1. HP

4.6.2.2. LP

4.6.2.3. Superheat

4.6.2.4. Suct Temp

4.6.2.5. Discharge

4.6.2.6. Evap Temp

4.6.2.7. HP 2

4.6.2.8. LP 2


4.6.2.10. Suct Temp 2

4.6.2.11. Discharge 2

4.6.2.12. Evap Temp 2

4.6.2.13. Return Air


4.6.2.15. RA Dew Point



4.6.2.18. OA Dew Point

4.6.2.19. Supply Air

4.6.2.20. Exhaust Air

4.6.2.21. Reheat Temp

4.6.2.22. Pool In

4.6.2.23. Pool Out

4.6.2.24. Pool 2 In

4.6.2.25. Pool 2 Out

4.6.3. Sensor Calibration

4.6.3.1. HP

4.6.3.2. LP

4.6.3.3. Superheat

4.6.3.4. Suct Temp

4.6.3.5. Discharge

4.6.3.6. Evap Temp

4.6.3.7. HP 2

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4.6.3.8. LP 2


4.6.3.10. Suct Temp 2

4.6.3.11. Discharge 2

4.6.3.12. Evap Temp 2

4.6.3.13. Return Air




4.6.3.17. OA Dew Point

4.6.3.18. Supply Air

4.6.3.19. Exhaust Air

4.6.3.20. Reheat Temp

4.6.3.21. Pool In

4.6.3.22. Pool Out

4.6.3.23. Pool 2 In

4.6.3.24. Pool 2 Out

4.6.4. AO Polarity

4.6.4.1. Modulated Heat

4.6.4.2. Blower Speed

4.6.4.3. Head Press 1

4.6.5. Digital Inputs

4.6.5.1. Blower On/Off

4.6.5.2. Compressors

4.6.5.3. Space Heater

4.6.5.4. Occupied

4.6.5.5. Pool 1 On/Off

4.6.5.6. Pool 2 On/Off

4.6.5.7. A/C Enabled

4.6.5.8. Emergency Heat

4.6.5.9. A/C Override

4.6.5.10. Heat Override

4.6.5.11. Freezestat

4.6.5.12. HP 1

4.6.5.13. HP 2

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4.6.5.14. LP 1

4.6.5.15. LP 2

4.6.5.16. Oil 1

4.6.5.17. Oil 2

4.6.5.18. Pump Fault

4.6.5.19. Exhaust 1 OL

4.6.5.20. Exhaust 2 OL

4.6.5.21. OACC 1 OL

4.6.5.22. OACC 2 OL

4.6.5.23. Heat Rec OL

4.6.6. Sample Rates

4.6.6.1. AI Samples

4.6.6.2. AI Samples 2

4.6.6.3. AI Sample Rate

4.6.6.4. DI Samples

4.6.6.5. DI Sample Rate

4.6.6.6. Refresh Sens

4.6.6.7. Refresh Sens2

4.6.7. Assignments

4.6.7.1. Analog Inputs

4.6.7.1.1. Return Air

4.6.7.1.2. RA Humidity

4.6.7.1.3. Supply Air

4.6.7.1.4. Outdoor Air

4.6.7.1.5. OA Humidity

4.6.7.1.6. Exhaust Air

4.6.7.1.7. Reheat Temp

4.6.7.1.8. Pool 2 In

4.6.7.1.9. Pool 2 Out

4.6.7.2. Analog Outputs

4.6.7.2.1. Modulated Heat

4.6.7.2.2. Blower Speed

4.6.7.2.3. Head Press 1

4.6.7.3. Digital Inputs

4.6.7.3.1. Blower On/Off

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4.6.7.3.2. Compressors

4.6.7.3.3. Space Heater

4.6.7.3.4. Occupied

4.6.7.3.5. Pool 1 On/Off

4.6.7.3.6. Pool 2 On/Off

4.6.7.3.7. A/C Enabled

4.6.7.3.8. Emergency Heat

4.6.7.3.9. A/C Override

4.6.7.3.10. Heat Override

4.6.7.3.11. Freezestat

4.6.7.3.12. No Airflow

4.6.7.3.13. Dirty Filter

4.6.7.3.14. Pump Fault

4.6.7.3.15. Exhaust 2 OL

4.6.7.3.16. Heat Rec OL

4.6.7.4. Digital Outputs

4.6.7.4.1. Heat Recovery

4.6.7.4.2. OACC

4.6.7.4.3. OACC 2

4.6.7.4.4. Pool 2 Compr

4.6.7.4.5. Pool 2 Aux

4.6.7.4.6. System Status

4.6.7.4.7. Network Dev

5. Service [Optional]

5.1. Force Contacts

5.1.1. Reset All

5.1.2. Ventilation

5.1.2.1. Blower

5.1.2.2. Blower Speed

5.1.2.3. OA Damper

5.1.2.4. Exhaust Fan 1

5.1.2.5. Exhaust Fan 2

5.1.2.6. Heat Recovery

5.1.3. Space Heating

5.1.3.1. Heat Stage 1

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5.1.3.2. Heat Stage 2

5.1.3.3. Modulated Heat

5.1.4. Pool Heating

5.1.4.1. Pool 1 Compr

5.1.4.2. Pool 2 Compr

5.1.4.3. Pool 1 Aux

5.1.4.4. Pool 2 Aux

5.1.5. Compressor 1

5.1.5.1. Contactor

5.1.5.2. Pump Down

5.1.5.3. Compr Pump

5.1.5.4. OACC

5.1.5.5. OACC2

5.1.5.6. Head Pressure

5.1.5.7. More Reheat

5.1.5.8. Less Reheat

5.1.5.9. Bypass Open

5.1.5.10. Bypass Close

5.1.6. Compressor 2

5.1.6.1. Contactor

5.1.6.2. Pump Down

5.1.6.3. Compr Pump

5.1.6.4. OACC

5.1.6.5. OACC2

5.1.6.6. Head Pressure

5.1.6.7. More Reheat

5.1.6.8. Less Reheat

5.1.6.9. Bypass Open

5.1.6.10. Bypass Close

5.2. Network

5.2.1. Ping

5.2.2. Console

5.3. Clear Alarm Log

5.4. Clear All Logs

5.5. Commission

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5.5.1. Tested

5.5.2. Commissioned

Menu Structure Description

This is a more detailed description of each menu item.

1. User Settings

1.1. Setpoints : If user password has been enabled, you will need to enter the password before you can change any

setpoint.

1.2. Date & Time : In this section you set system time properties. You can set the date, time and time zone.

You can also set what date time format that should be used. Date is always edited in Year-Month-Day syntax and the

time is always edited in 24-hour clock format not matter what the format settings are. Time zone can be set to -3:30,

-4:00 to -10:00 and GMT time. The following date formats are supported: Y-M-D, D/M/Y, M/D/Y and Full. The

last format will be spelled out as Jan 1, 2006. Clock is either a 12 or 24-hour clock. Note that if the unit is connected

to the Internet, you do not need to set the clock. The clock will automatically be synchronized with a time server.

Time zone and date/time formats still needs to be set.

1.3. System Info : The System Info screen lists some useful information when troubleshooting the system like

Software and Board version, current IP and MAC address and optional configuration settings.

1.4. Occupied Schedule : If user password has been enabled, you will need to enter the password before you can

change the schedule. You can enter up to 3 scheduled items. Each item determines when the room is Occupied by

specifying a start time and a stop time. You also specify which day of the week the scheduled item applies (Monday-

Sunday, Workdays, Weekends or All). If there are conflicting items then the priority goes to day items (Monday-

Sunday) followed by Workday and Weekends and last All. Use this to your advantage by specifying a default schedule

using All and then add a schedule item for days where the default does not apply (e.g. Weekends, Sunday).

1.5. Filter Schedule : Use the filter schedule to determine how often there will be a Dirty Filter alarm reminding you

that all filters should be replaced. Date shows the next date a Dirty Filter alarm will be tripped. You can manually

change this date to any date you like. Interval specifies number of months until next Dirty Filter alarm after the alarm

has been cleared. Note that the alarm will not be cleared on a system restart. You have to clear the alarm from the

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active alarms list. When cleared, the date for next alarm will automatically be changed to a date using this interval

and the current date.

1.6. Display : Use Backlight to enable/disable the keypad backlight. Use Temp Unit property to set temperature unit

to be used in the system (Celsius or Fahrenheit). Reset Display controls how long the operator panel will stay idle at a

menu screen before being returned to the main sensor screen.

1.7. User Password : Here you can enable user passwords (disabled by default). You can also change the user

password and set for how long the user password protected menu items should stay open after they have been

unlocked (retention time).

1.8. Remote OP : This menu selection is only visible on a remote OP (operator panel connected to the board using a

serial port). Under version info you can see the software version of the remote OP as well as the minimum main

board software version required to be able to communicate with a main board. Port Configuration is used to configure

the remote OP end of the serial port interface. Baud Rate sets the speed of the connection. Echo Test defines if we

will do an echo test every time we transmit data over the port. Normally all data should be echoed back and therefore

adding the echo test enable us to have one more test to ensure data was transmitted with no errors. However, if there

is a minor hardware problem with the port chip, this will cause the port not to work at all. Disabling the echo test

might enable us to still use the port even with the hardware error. Reply Delay defines for how long we will wait for a

reply message before considering it a communication fault.

2. Alarms

2.1. Current Alarms : The current alarm lists shows all alarms that have not been cleared. You can clear an alarm by

selecting the alarm using number key and then pressing the Enter key to clear the alarm. Note that some alarms are

tied to a physical device that automatically will clear the alarm when device clear the fault condition. You can still

clear this alarm from the alarm list but the alarm will trip right away if the device has not cleared the fault.

2.2. Alarm Log : The alarm log lists all alarms since the alarm log last was cleared (from the Service menu).

Most recent alarm at the top. The top line shows the date for selected alarm. Use arrow keys to select an

alarm. Selected alarm is indicated by an arrow in the left margin. The alarm log will scroll one alarm at a

time rather than a page at a time. If pressing the up key when the first alarm is selected, alarm log will be

refreshed.

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3. System Control

3.1. Start/Stop Blower: Start and stop main blower. Note that the blower might not come when turning it on. There

can be an alarm condition preventing it from starting (e.g. blower overload, voltage monitor fault or firestat). When

selecting Normal Mode at startup, the blower will automatically be started. To not run the blower you will have to go

to this menu and turn blower off. There might be up to a minute delay before blower starts due to the voltage monitor

fault signal not being cleared. When selecting Service Mode at startup, the blower will not be started.

3.2. System Restart : When selecting System Restart you will see a confirmation screen where you have to confirm

that you want to restart the system. Pressing 2 or the Back button will cancel this request.

3.3. System Status : The status screen shows the status for different internal system components. Its main purpose is

for troubleshooting a running system where the information here can be passed back to tech support. The status

feature has been grouped into 6 areas. Environment shows status for the environment control (Air Temp, Humidity

and Pool Heat) including air heater and pool heater. The compressor area shows the status for all compressors in the

system. The ventilation area shows the status of the different ventilation related components (including heat

recovery). The network area shows the status for network related components. The serial ports area show serial port

status. The control status area shows internal control parameters.

3.4. Purge : By selecting the Purge menu item you will get to the Purge activation screen. At this screen you can set

the length of time the system will purge and start/stop purging. At the bottom of the screen you can see the current

status. It can show Off, PendingPurge or number of minutes remaining of ongoing purge. PendingPurge means that

we are waiting for the compressor(s) to stop before we can start purging. The compressors have been notified that they

need to stop. Note that you only can start purge if Purge has been enabled under Factory Settings.

4. Factory Settings : To reach these settings you need to enter a service password.

4.1. Ventilation

4.1.1. Options : Purging enables and disables the purging feature. The Economizer property determines how the

economizer feature will be used. Setting it to None disables the feature, setting it to A/C enables it for cooling only,

setting it to Dehum enables it for dehumidification only and sertting it to Full enables it for bot cooling and

dehumidification. Eco Offset OA is an offset below return air setpoint. The return air setpoint minus this offset is the

highest outdoor air temperature at which the economizer will start. The minimum outdoor air temperature is

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controlled by the economizer setpoint. Eco Offset DP is an offset below return air dew point. The return air dew point

minus this offset is the highest outdoor air dew point at which the economizer will start. Fire Reset property controls

how the system will recover after a Fire Alarm. When set to auto, system will automatically go back to normal once

the alarm is cleared. When set to Manual, a System Restart is required to make the system operational again.

4.1.2. Blower : Normal Speed sets the normal main blower running speed as a percentage of full capacity. Max Speed

sets the max main blower running speed as a percentage of full capacity. Blower will only switch to max speed if unit

is equipped with a high speed override input.

4.1.3. Timers : Stabilize is how long time system will wait for sensors to stabilize after blower has started. No other

components will start until sensors are stable. Freezestat 1 is the Freezestat 1 alarm debounce timer. Freezestat 1 is

tripped when supply air drops below the freezestat setpoint. Freezestat 2 is the Freezestat 2 alarm debounce timer.

Freezestat 2 is tripped if supply air drops stays below the freezestat setpoint after Freezestat 1 has been tripped. No

Airflow property is the No Airflow debounce timer. Purge Time is for how long time purge will run when started.

Setting it to 0 means purge will run until manually stopped. Dirt Filt Dly property is the Dirty Filter debounce timer if

the dirty filter switch has been enabled.

4.2. Compressors

4.2.1. Configuration : Up to two compressors can be configured. The following parameters can be set for each one.

Use Available property to make compressor available as a resource. Use Resource ID to determine in which order

compressors will be used.

4.2.2. Options : Use Enabled property to enable or disable usage of compressors. Compressors are disabled by default

when unit is shipped and still in Commission mode. The Design property defines what type of compressor circuit

design is used in this unit. Classic design uses Reheat and A/C valves to control reheat temperature. Protocol design

uses a modulating reheat valve. Refrigerant sets the type of Refrigerant used in the system. This will affect some of the

pressure levels used to control the compressors. OACC Type sets the type of OACC used in the system. The LowHigh

option is a 2 stage configuration where the two stage contacts are exclusive of each other (i.e. for stage 2, stage 1

contact is off and stage 2 contact is on). Compare this with the stage 2 option where both contacts are on for stage 2

fan speed. Emergency Heat determines if compressor can be used has a space heater. When set to Yes, compressor

will start on a heating demand. Note that the space heater will be disabled when this options is enabled. The

Superheat property defines the minimum superheat level. Reheat Steps defines the number of steps it takes to move

reheat valve from fully closed to fully opened. Divide reheat time with reheat steps to see how many seconds the valve

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will move every time there is a demand for more or less reheat. Reheat Time is the time it takes the reheat valve to

move from fully closed to fully opened. Reheat Calib timer controls how long the reheat valve will continue moving

after it reaches either fully closed or fully opened. This is used to calibrate valve position to avoid any drifting. BPD

Steps defines the number of steps it takes to move bypass damper from fully closed to fully opened. BPD Turn Time is

the number of seconds the bypass damper will move in one step. Number of steps times this timer is the total time it

takes the bypass damper to move from fully closed to fully open. BPD Stabilize is the number of seconds the bypass

damper will wait after moving one step before allowing another request to move damper. Use the Partial Mode

property to control if unit will be using partial heating mode for compressors in a classic design unit. Partial heating

mode is when both the reheat and the A/C valves are open. The Partial Transit property should only be changed after

talking to a Seresco engineer. It is used to solve a problem where both the A/C and Reheat solenoids are open and

one of them closing but not closing properly. Set this property to 0 to disable this feature. PD At Start determines if

compressor will do an initial pump down at startup if LP is above start level. PSI Monitor is a timer used for

monitoring low and high pressure. Low pressure is monitored to not rise too high and high pressure is monitored to

not drop too low. A check is made every time this timer expires. If either low or high pressure indicates a bad pressure

7 times in a row, a compressor fault alarm will be tripped.

4.2.3. Timers : Min Startup timer controls the minimum time compressor will wait before starting compressor even if

minimum Low Pressure level is met. Stabilize timer controls for how long time the compressor will run before we

enable the Low Pressure alarm. During this time the system will still monitor for a low pressure level reaching

vacuum levels using the low pressure transducer. Min Run Time timer controls the minimum time the compressor has

to run before it can be stopped. Min Stop Time control the minimum time the compressor has to be stopped before

being started again after a normal stop. Alarm Stop control the minimum time the compressor has to be stopped

before being started again after an alarm. The Anti Block timer is used when deciding if the compressor should be

started even if the low pressure has not reached minimum level. It is also used decide for how long we will wait for the

low pressure to reach its shutoff level before stopping the compressor anyway. Superheat Dly timer is the superheat

debounce timer. Superheat alarm condition must persist for this amount of time before an alarm is tripped. SucTemp

Dly timer is the suction temperature debounce timer. High suction temperature alarm condition must persist for this

amount of time before an alarm is tripped. Oil Fault timer is the time after compressor startup before oil alarm

detection is enabled.

4.2.4. Pressures : LP Vacuum pressure setting controls at what Low Pressure level compressor will trip on Low

Pressure alarm while compressor is in stabilizing mode. LP Alarm pressure setting controls at what Low Pressure

level compressor will trip on Low Pressure alarm once it is past Stabilize state. LP Start pressure setting controls at

what minimum Low Pressure level compressor will start. Note that there also are some timers controlling when

compressor can start (Min Startup and Anti Block). LP Normal pressure is the normal low pressure runtime level.

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This pressure in conjunction with the LP Deadband is used to determine when bypass damper will open or close. LP

Deadband defines the deadband around the LP Normal pressure. When LP drops below deadband, bypass damper

will close, when rising above deadband, bypass damper will open. LP Max pressure setting controls the maximum

Low Pressure level we allow the compressor to run at. Pressure has to stay above this level for a short while and the

trend not showing any tendency to recover. HP Min pressure setting controls the minimum High Pressure level we

allow the compressor to run at. Pressure has to stay below this level for a short while and the trend not showing any

tendency to recover. HP Alarm pressure setting controls at what High Pressure level compressor will trip on High

Pressure alarm. HP Relief pressure setting controls at what High Pressure level compressor will engage HP relief

mode. HP OACC Min pressure setting controls at what High Pressure level Outdoor Air Condenser will start

(minimum capacity or stage 1). HP OACC Max pressure setting controls at what High Pressure level Outdoor Air

Condenser will run at maximum capacity (max capacity or stage 2). OACC HP Change determines the sensitivity of

the OACC head pressure control valve. Valve will only be adjusted if HP has changed at least as much as specified

with this property since the last adjustment. OACC Deadband is used to determine when to turn off an OACC stage.

OACC Min or Max pressure level minus deadband is when OACC stage will be turned off.

4.3. Space Control

4.3.1. Room Temperature : The Deg*Min On/Deg*Min Off properties controls for how long the control logic will

wait until increasing or decreasing the supply air setpoint. Setpoint Adj determines number of degrees to increase or

decrease the supply air setpoint every time setpoint is changed.

4.3.2. A/C : The Operation property determines when A/C mode will be used throughout the year. Default is All

Year. Set it to Disabled to completely disable the A/C feature. Set it to Summer Only to only use A/C mode in

summer time. Summer time is determined by the Disable A/C setpoint. Outside air temperature has to be above this

temperature for it to be considered summer. The Deg*Min On/Deg*Min Off properties controls for how long the

control logic will wait until adding or removing a Cooling stage after a stage has been added/removed. The Sensor

property determines how cooling will be controlled. Supply means that space temperature will be controlled by using

supply air sensor only. Return means that the space temperature will be controlled by the Room Temperature

controller using the return air sensor.

4.3.3. Heating : Type sets heating type. The Deg*Min On/Deg*Min Off properties controls for how long the control

logic will wait until adding or removing a Heating stage after a stage has been added/removed. The Sensor property

determines how heating will be controlled. Supply means that space temperature will be controlled by using supply air

sensor only. Return means that the space temperature will be controlled by the Room Temperature controller using

the return air sensor. Mod Step Size defines the increments for the modulated signal when heater is configured as

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modulated heater. Stage 2 On controls when the second stage digital output will be turned on for a modulated heater.

First stage is turned on when heating is started.

4.3.4. Humidity : The Deg*Min On/Deg*Min Off properties controls for how long the control logic will wait until

adding or removing a Dehumidification stage after a stage has been added/removed. Temp Offset property is the

offset from the return air temperature where dehumidification will not operate. If temperature is outside this range,

dehumidification ill not come on even the humidity is above the high deadband. However, if dehumidification already

is running, the will keep on running even if the temperature moves outside the range. High Humidity property is the

offset above setpoint at which dehumidification will start no matter what the return air temperature is.

4.3.5. Deadbands : This section is used to configure setpoint deadbands. Space temperature setpoints can be set in

1/10th of a degree.

4.4. Pool Control : Use Pool 1 and Pool 2 properties to enable pool heating. Pool heating can be enabled for

compressor heating only, auxiliary heating only or to use both resources for heating. Contact 2 defines how the pool 2

heating contact will be used. Default means it will be used for pool 2 heating. Stage 2 means it will be used for units

where pool heating coil has been divided into two stages. Use bypass if this software version is used on an older unit

where a bypass valve was used. 100% Heating defines how pool heating can use compressor. Set it to Yes to let pool

heating run compressor with only pool heating valve open. Heat Sink determines at what reheat level pool heating can

be used as a heat sink feature. This property only applies to protocol design units. Min Out Temp defines the

minimum pool out temperature offset above pool in temperature when pool is heated using compressor pool heating

coil. If below this level, a high water flow alert will be tripped but pool heating will continue. High Flow Dly is a high

water flow alarm debounce timer. Pool out temperature has to be below minimum temperature level for this amount

of time before alarm is tripped. HP Pool Fault is a timer used in determining if a HP trip was caused by turning

compressor pool water heating. If HP trip occurs within this time frame, HP trip will be tagged as being caused by

pool water heating. There will also be a water flow fault alarm. HP Relief is a timer that defines for how long pool

heating will run in HP relief mode before going back to normal mode. Waterflow Rec property controls for how long

a waterflow alarm will stay active and pool heating will remain in recovery mode. After this time, the pool heating

control will go back trying to heat pool again if there still is a demand for it and compressor is running. Note that

auxiliary pool heater will still be used when recovering from a waterflow alarm. Max Trips Time determines in what

time frame you are allowed to have 3 water flow fault alarm trips without locking out pool water heating.

4.5. Network

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4.5.1. TCP/IP : Set DHCP to use Dynamic IP and set it to No to use Static IP. In the first case, the IP, Mask, GW and

DNS property will be set automatically and you will be able to see what they are set to (as soon as a network

connection has been detected and a DHCP server has been found). IP is the systems IP address. Mask is the network

mask. GW is the IP address for the gateway. DNS is the IP address for the Domain Name Server. Link Monitor is

how often the system will check that there still is a physical network link. If you unplug the Ethernet cable, it can take

up to this time before it is detected. Start Device is a timer that is used at startup of a network device. The Network

Device digital output has to be assigned to a terminal. Regular network setup will not start until this timer expires.

Reboot Device is the number of minutes the network can be down until unit will reboot the network device (if

assigned to a terminal). Reboot means turning off Network Device output and then turning it back on. Reboot Delay

is how long the network device will stay off on a reboot request before turning it back on again.

4.5.2. Serial Ports : Port properties are the same for all ports except where noted. User defines the user of the port.

Default is Seresco which means the port is opened for inbound traffic using the Seresco protocol. Other users are

other protocols like LON and Modbus as well as 3&4 compressor slave board communication. Baud Rate, Databits

and Parity defines your common serial port configuration parameters. Flow Control defines if hardware flow control

should be used. Can only be configured for the RS-232 port (port B). Echo Test defines if we will do an echo test

every time we transmit data over the port. Normally all data should be echoed back and therefore adding the echo test

enable us to have one more test to ensure data was transmitted with no errors. However, if there is a minor hardware

problem with the port chip, this will cause the port not to work at all. Disabling the echo test might enable us to still

use the port even with the hardware error. Reply Delay defines for how long we will wait for a reply message before

considering it a communication fault.

4.5.3. WebSentry : These properties controls WebSentry connection. Set Enabled to No to disable WebSentry. You

can do this if you temporarily want to disable WebSentry connections. Also you should do this if a unit is not

connected to the Internet to avoid unnecessary attempts trying to detect a physical network link. Use DNS controls if

DNS should be used to resolve the IP address associated with the hard coded WebSentry server name. You should set

this to No if there seems to be a problem resolving the IP address and instead use the IP property to define the IP

address. IP is the WebSentry server IP address. Use this property to configure the IP address or to see what it is if

DNS is enabled. Port is the WebSentry port to connect to. This is configurable in case the port will change in the

future. Comm Interval is how often the system will try to connect to the WebSentry server between disconnects.

Comm Segment is how often the system will try to connect to the WebSentry server between disconnects when we

can not transmit all non-sent data in one session. Stay Alive is how long the TCP connection will stay active from the

last time a message was received from the WebSentry server. Normally the WebSentry server should disconnect before

this time.

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4.5.4. BACnet : These properties controls BACnet connections and are only available if the CommandCenter has

been loaded with BACnet support. Set Enabled to ReadWrite to enable BACnet for read and write support. Set it to

ReadOnly to only let BACnet interface read data from unit (no changes allowed). Set Interface to BACnet interface

type. Currently only Ehernet and IP is supported. Use Device ID to set a unique device ID for unit on the BACnet

network. Port can be used to change the default port setting. The Heartbeat timer is used when BACnet interface is

controlling some sensors. If no message is received within this time, unit will rollback to system installed sensors.

Setting timer to 0 means that timer will not be used.

4.5.5. Modbus : Use these properties to configure Modbus communication.

4.5.6. LON : Use these properties to configure LON-Modbus gateway communication. Set Enabled to ReadWrite to

enable LON for read and write support. Set it to ReadOnly to only let LON interface read data from unit (no changes

allowed). Use Interface to define which serial port to use for gateway communication. Refresh Rate defines how often

unit will check gateway for changed data.

4.6. Inputs/Outputs

4.6.1. Sensor Type : The sensor types controls how an input signal is translated into a value. Note that some sensors

that are available under sensor calibration are not available under sensor types. These are temperature sensors that

never should be disabled and for which there are no other sensor type that can be used except Thrm. The following

sensor types are available:

Thrm, thermistor sensor to be used for all temperature sensors.

GSRA, Greystone return air sensor.

GSRH, Greystone RH sensor.

RH, General RH sensor.

SG145, Saginomiya transducer, max 145 psi.




JC100, Johnson Controls transducer, max 100 psi.

JC500, Johnson Controls transducer, max 500 psi.

BMS, Building Management System controlled sensor.

Calc, Calculated sensor.

4.6.2. Sensor Usage : The sensor usage option determines how a sensor is being used. There are four values that can

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be set. None will disable sensor. It will not be used for control and will not be displayed on sensor screen. Dflt is the

default setting for most sensors. It means that that sensor will be used as determined by the system. For sensors used

for control, sensor will used both for control and it will also be displayed on sensor screen. Set sensor to View to

disable sensor for control but still have it displayed on sensor screen. Set sensor to Ctrl to not show it on sensor screen

but still have it enabled for control.

4.6.3. Sensor Calibration : All sensor calibration values are changed the same way. You use the up and down arrow to

change the value to a few steps above or below 0.

4.6.4. AO Polarity : These options are used to set the polarity of the analog outputs. 0V means that device is off or

closed at 0 volts. 10V means that device is off or closed at 10 volts.

4.6.5. Digital Inputs : These options are used to enable/disable some digital inputs. Several of them are optional

inputs that can be used to control certain components and features of the system.

4.6.6. Sample Rates : The AI Samples, AI Samples 2 and AI Sample Rate properties are used to fine tune the way

analog inputs are read and translated into sensor readings. A sensor reading is the average of all read samples. AI

Samples 2 is used for all compressor related sensors and AI Samples 1 is used for all other sensors. The Refresh Sens

and Refresh Sens2 properties determines how often sensors will be read. Sensor reading will also be generated when

there is a change in the sensor reading. Refreshing sensors on a regular basis prevents us from getting stuck with no

sensor readings for a long time when the system is stable. Refresh Sens2 is used for pool water related sensors and

Refresh Sens is used for room conditions sensors. The DI Samples and DI Sample Rate properties are used to fine

tune the way digital inputs are read and translated into alarms or other inputs. A digital input will signal a state

change when all samples are the same and are different from current saved state.

4.6.7. Assignments : These settings are used to assign an input or output signal to a physical input/output on the

board. The internal input/output id is being used to reference the physical input/output. A wiring diagram is needed

to determine the board terminal.

5. Service : To reach these settings you need to enter a service password.

5.1. Force Contacts : Force Contacts is used to test all the Analog and Digital Outputs. This overrides any internal

control of corresponding features and is just a way to physically test that a contact is working. Selecting Reset All will

reset all contacts back to the Off position.

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5.2. Network

5.2.1. Ping : The ping feature is used to test the IP network. To use ping, set the ping address and then select start. The

first result line shows the IP addresses you are pinging from (units IP address) and the second line will show 4 time

values in milliseconds. Ping will send 4 messages to specified address and measure in milliseconds how long it will

take to get a reply. If no reply within 5 seconds the result will show Fail for that particular ping request.

5.2.2. Console : The console is currently only used to monitor serial port messages. Select the serial port to monitor by

using the arrows keys. Select 1 to start monitoring. To stop/pause messages, you can press key 2 anytime. Press Enter

to clear the screen. Select back top stop console or to go back and select another serial port.

5.3. Clear Alarm Log : Selecting Clear Alarm Log will display a confirmation screen where you have to confirm that

you want to clear the alarm log. Pressing 2 or the Back button will cancel this request.

5.4. Clear All Logs : Even though you only can look at the alarm log from the control panel, there are several other

logs used as well. These logs can be read using WebSentry if the unit is connected to Internet. Use Clear All Logs to

clear all the logs and not just the alarm log.

5.5. Commission : When control board initially is configured loaded with the latest control software, unit is prepared

to make it safe and easy to use when testing unit before delivery to customer. When test completed, the Tested option

is changed to Yes and can never be changed back again. When unit has been tested, the compressor Enabled property

will be changed to No. When Commissioned option still is set to No, unit will start up in service mode. It is not

possible to start the unit in Normal Mode. The blower can be started anytime but to enable the compressors and to be

able to change the Commissioned option, a factory password is required. When changing Commissioned to Yes, all

the logs will be cleared and the unit will do a system restart. Now at startup you will see the normal startup screen

with 2 selections, Normal Mode and Service Mode. The Commissioned option can be changed back to No if needed.

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G-

Issue Date : 2011-09-20 Section H - Routine Maintenance

Routine Maintenance

WARNING Disconnect all electrical power, including remote disconnect, and discharge all

energy storing devices before servicing. Follow proper lockout procedures to ensure the power cannot be

accidentally energized. Failure to follow provided safety warnings and labels could result in serious injury

or death.

WARNING When it is necessary to work with live electrical components, have a licenced

electrician or other qualified persons perform the required maintenance.

WARNING Danger or moving mechanical parts, high voltage power, elevated pressure and

temperature ! When performing maintenance activities, lock out the unit to prevent accidental start-up.

When service is required, call a qualified refrigeration mechanic.

Routine Maintenance Checklist

Seresco Technologies Inc.'s products are built for dependable and safe operation with minimum maintenance. Periodic

maintenance is required, however, to ensure continuous safety and maximum operating efficiency. Suggested maintenance

operations are listed in the table below with the recommended service intervals. Please note that these are general guidelines

and should be adjusted accordingly to match facility operating conditions.

Table 1. Routine Maintenance Requirements

Frequency Maintenance Operation

Weekly Observe unit weekly for any change in running condition and unusual noise

MonthlyClean or replace air filters if clogged or dirty

Verify that all set-points are correctly programmed as specified by the facility operator

Quarterly

Inspect and clean drain pans

Tighten electrical connections if required

Check and tighten, if requires, pool water hose clamps and sensor mounts

Inspect coils for dirt build-up

Check that the P-trap is primed (filled with water). It is good practice to to pour some water into the drain pan to ensure that the P-trap is primed and operational

Check and lubricate motor bearings. Refer to the motor manufacturer's instructions

Check outdoor air louvres for accumulation of dust and clean as required

H-1

Section H - Routine Maintenance Issue Date : 2011-09-20

Yearly

Inspect the unit casing for corrosion. If damage is found, clean and repaint the affected surface with a rust-resistant primer

Clean the fan wheel(s) and motor shaft(s)

Inspect and clean drain pans

Check damper operation

Inspect electrical components, wiring and insulation

Rotate the fan wheel(s) and check for obstructions and rubbing

Lubricate motors as directed by motor manufacturer

Check gasket condition on all doors to ensure an airtight seal

Check for loose external or internal parts, paying careful attention external components

Check bolts on compressors, motor mounts, unit bases and coils and tighten if required

Verify that the airflow around the remote condenser or dry cooler is unobstructed

Component Maintenance

Filters

Replace filters when dirty. Check filters located in main filter wall, outside air intake and exhaust fan opening. Filters should

slide out of their tracks without difficulty. Replace with filters of equivalent size and rating. See section Z - Annex for filter

sizes and quantities.

Drain Pans

WARNING Hazardous chemicals ! Cleaning agents can be highly acidic or alkaline. Handle all

chemicals carefully and use appropriate personal protective equipment (PPE). Refer to the cleaning agent

manufacturer's Materials Safety Data Sheet (MSDS) for safety and handling information. Failure to follow

all safety instructions could result in serious injury or death.

Note : Do not walk on the drain pans. Doing so will cause damage and impair drainage.

To clean drain pans:

1. Disconnect all electrical power to the unit

2. Remove any standing water

3. Scrape solid foreign material off of the drain pan and vacuum to remove particulate matter

H-2


4. Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved

sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion

5. Allow to dry completely before putting the unit back into service. Dispose of all contaminated

materials

Impellers / Fans

To clean fan blades:


2. Scrape solid foreign material off of the fan blades and vacuum to remove particulate matter

3. Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved

sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion

4. Allow to dry completely before putting the unit back into service. Dispose of all contaminated

materials

Motors

Inspect fan motors periodically for excessive vibration or temperature. For bearing lubrication and other maintenance

activities, see manufacturer's literature provided in the appendix.

Coils

WARNING Hazardous pressures ! Coils containing refrigerant under pressure must not be

cleaned using a solution over 150 ºF. Failure to follow these safety precautions could result in coil bursting,

which could result in serious injury or death.

To clean coils:


2. Wearing the appropriate personal protective equipment (PPE), use a soft brush to remove loose debris

from the coil

3. Install a block-off to prevent spray from going through the coil and into a dry section of the unit and /

or system ductwork

4. Mix a high quality coil cleaning detergent with water according to the manufacturer's instructions

5. Place the mixed solution in a garden pump-up sprayer or high-pressure sprayer. If a high-pressure

H-3


sprayer is to be used:

a) Maintain minimum nozzle spray angle of 15 degrees

b) Spray perpendicular to the coil face

c) keep the nozzle at least 6 inches from the coil

d) Do not exceed 60 psi

6. Spray the leaving side of the coil first, then the entering air side

7. Thoroughly rinse both sides of the coil and the drain pan with cool, clean water

8. Straighten any coil fins that have been bent during the cleaning process

9. Confirm the drain line is clear

10. Replace all panels and parts and restore electrical power to the unit

11. Dispose of all contaminated materials

Insulation

Note : Microbial growth ! Wet interior insulation can become an amplification site for microbial growth

(mold), which may cause odours and damage to the equipment and building materials. If there is evidence

of microbial growth on the interior insulation, the insulation should be removed and replaced prior to

operating the system.

Accumulated dirt and other organic matter exposed to water or extended periods of high relative humidity (60 percent or

higher) can support microbial growth, which must be removed to prevent the unit from becoming a contaminant source. If

evidence of contamination exists, determine and eliminate the cause, remove the contamination and sanitize the affected

area.

Refrigerant Charging Procedure

Repairs or maintenance on refrigerant containing components or pipes will require reclaiming and then charging the unit.

The procedure outlined below demonstrates the correct method for charging refrigerant loops on Seresco Technologies Inc.'s

dehumidifiers.

Pressure Testing Procedure

Perform a pressure test before vacuuming and charging the system to ensure that there are no leaks.

Pressure test the pipes for at least four hours using nitrogen at 350 psi when using R-407C refrigerant or

H-4


500 psi when using R-410A refrigerant

Perform soap tests at all joints

If the pressure drops by more than 10 psi over the four-hours, then the test has failed

Evacuate the nitrogen

Vacuuming Procedure

It is crucial to vacuum the system to ensure that there will be no contamination when the unit is charged with refrigerant.

The whole system or only a portion can be put under vacuum. Make sure to replace the oil in the vacuum pump before every

use.

Fasten hoses as shown in the attached diagram

Attach a Micron gauge to monitor vacuum levels in the system.

The vacuum should be below 500 microns. Check the gauge after 15 minutes, it should not have

increased by more than 15 – 20%.

If 500 microns is not reached after 1 hour, redo the pressure test. Soap test everything including the

hose connections.

Break the vacuum by opening the rotolock valve on the receiver or by charging the receiver using 5 – 10

lb of refrigerant.

Close the tank, all solenoid and ball valves before removing the vacuum gauge and vacuum hose.

Units 8 tons and larger feature a removable core filter drier. In order to clean the core only a portion of the system needs to

be evacuated.

Close the rotolock valve on the receiver outlet and pump down all the refrigerant in to the receiver

Remove, clean and replace the filter dryer core

Draw vacuum from the line as shown in the diagram.

Repeat the bullet points listed above, but note that vacuum may only reach 600 – 800 Microns due to small refrigerant leaks

through the rotolock valve at the receiver. There are several possible causes which could prevent the vacuum pump from

reaching 500 Microns. Ensure that all hose connections are tight. Contaminants in the lines could cause the vacuum pump to

reach full vacuum very slowly. Traces of refrigerant could also be impeding the vacuum.

Charging Procedure

Check the unit label for the proper refrigerant type (R-407C or R-410A)

Turn the stem on the receiver rotolock counter-clockwise to “back-seat” the stem (close the rotolock)

H-5


Partially connect the charging hose and purge the line before fully connecting the hose

Figure H-1. Rotolock valve with cap (left, highlighted) and without the cap exposing the stem (right)

If charging the unit:

“Front seat” the stem by turning clockwise.

Charge the system with the required amount of refrigerant. Watch the pressure closely because the

system will charge quickly.

Back seat the stem again before disconnecting disconnect the hose.

If only charging 5-10lb to break the vacuum:

Turn the stem counter-clockwise to the halfway position.

Charge the required amount of refrigerant. This will be very quick.

Back seat the stem again before disconnecting the hose.

H-6


Outdoor Air Balancing

The amount of outdoor air introduced into the unit varies by season. Seresco Technologies Inc. provides manual balancing

dampers with all outdoor air equipped units. Even if a unit mounted motorized air damper is installed, the manual damper

will also be installed. There are two types of manual dampers depending on the size of the unit.

NE/NP-004 to -016 and NE/NP-2xx Series

Note that the Outdoor Air filter box contains two perforated sliding plates as shown in Figure H-1. Adjust the manual

damper by turning the black knob to slide one plate along the other. Align the holes for maximum air flow or misalign the

holes to block or dampen the airflow.

Figure H-2. Outdoor Air Filter Box

For NE/NP/NV-018 to NE/NP/NV-120

To adjust the outdoor air balance, first remove the filters. The manual damper consists of two perforated plates, one of which

slides on top of the other. To adjust the air balance loosen all the screws and slide the plate to obtain the desired setting. Re-

tighten all the screws.

H-7


Figure H-3. Outdoor Air Filter Box

Figure H-4. Outdoor Air Tightening Screw (highlighted)

H-8


Mechanical Vestibule Access Steps

The service steps displayed in Figure H-5 act as a step ladder giving easy access to the mechanical vestibule. The best place

to store the steps is on right of the vestibule between the compressor stand and the unit wall. Place them into the slots at the

front of the vestibule stand as shown and make sure they are secure before stepping on or placing any weight on them.

Figure H-5. Compressor stand step

Note that for unit models NE-018 to NE030 there is a lower step placement available on the outside of the unit as shown

below.

Figure H-6. Mechanical vestibule step on base rail

H-9



H-10

Issue Date : 2011-09-20 Section X - Troubleshooting

Troubleshooting

This section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact Seresco Technologies

Inc.'s service department.

Two user-friendly service tools are critical in troubleshooting any issues with Seresco's dehumidification systems: the

WebSentry remote monitoring software and automated system alarm logs. WebSentry remote monitoring software allows

the collection of comprehensive unit performance data and space conditions via the Internet. This option is default on all

units with CommandCenter controls and has proven to be an extremely effective service tool. To function correctly, this

requires the unit to be connected to a local network with Internet access. System Alarm Logs detail information on alarm

situations, including the type of alarm, faults and time to help service technicians narrow down possible cause(s) of the

problem(s).

Troubleshooting Steps

1. Collect information from unit owner/maintenance team about problem(s)

2. Refer to the provided Installation, Operation and Maintenance manual and the unit label for additional

information

3. Perform a basic visual inspection of the unit

4. Check the System Alarm Log for the latest alarm(s)

CAUTION If the unit is powered down: before powering up the system again, ensure that it is safe

to do so.

5. Refer to the list of common problems provided below for probable causes and suggested solutions

6. If you require further assistance, please feel free to contact Seresco's Service and Technical Support (STS)

department

Contacting Seresco Service and Technical Support (STS)

The next availible service technician can be reached by phone at (613)-741-3603, followed by 2, or by e-mail at

[email protected]. When contacting Seresco STS, please have the following information on hand:

− Your name

− Service company name

− Phone number

− Seresco unit serial number (8 digit number on the unit label i.e. 11011800)

X-1

Section X - Troubleshooting Issue Date : 2011-09-20

WebSentry Connection Troubleshooting Guide

Ethernet cable connected and operating

First thing to check is that the Ethernet cable has been hooked up properly and is operating normally. Use the LED’s by the

Ethernet socket to verify this. The LED’s are the two white square components on the mini board with the Ethernet socket.

The one closest to the socket should be solid green and indicates a solid physical connection. Unplug cable at the unit or at

the other end and this LED will go blank.

If cable is connected at both end and the LED still does not lit up, it is very possible the Ethernet socket itself is faulty.

Connecting a network cable between a laptop and unit can determine that indeed the Ethernet socket is faulty and that there

is not a faulty router port or faulty cable.

The second LED is yellow and will blink when there is communication.

Firewall settings

The unit will try to connect to the WebSentry server once a minute using port 1030. Server name is websentry.seresco.net.

Use ping to determine IP address associated with this IP address if this is needed for any firewall settings.

If network has a firewall, port 1030 must be open for communication or at least for the IP assigned to unit or the MAC

address for the unit or to/from the Seresco domain name or server IP.

The MAC address can be found under System Info using the local keypad. ‘*’ translates to 00:90:C2 so that if MAC shows

*:D1:2A:49 the full MAC address is 00:90:C2:D1:2A:49.

Checking network communication status

Check status of network communication from the local keypad. From main screen select Main Menu (1) - System (3) -

System Status (5) - Network (4).

TCP/IP should be saying Up. If it says PendingUp, there is a problem with establishing a physical connection. Network

cables and router/switch needs to be checked. Ensure light over port where unit is connected is lit up.

WebSentry will say Idle when waiting to connect to server (connects once a minute). When connected you will either see

Receive or Send. If it shows Connecting for several seconds it means there is a problem establishing a connection to the

server. Usually it will toggle between Idle and Connecting when a proper connection is not established. Check TCP/IP and

WebSentry configuration settings.

X-2

Issue Date : 2011-09-20 Section X - Troubleshooting

Checking TCP/IP configuration settings

Unit can be configured for dynamic or static IP. From main screen select Main Menu (1) - Factory Settings (5) - Network (5)

- TCP/IP (1). If asked for a password at Factory Settings selection, enter 813.

DHCP set to Yes is for dynamic IP and if set to no, unit is configured for Static IP.

Dynamic IP

You should see an IP and Mask assigned (* means 255). This is assigned by the router to which the unit is connected. On

second page you should also see IP's assigned to GW (Gateway) and DNS.

If any of these IP’s are not assigned properly (showing 0.0.0.0 for instance), there is a problem with the router assigning IP

info to the unit.

Static IP

IP, Mask, GW and DNS all have to be configured correctly or unit will not be able to communicate with the WebSentry

server. This information should be known by the IT group managing the local network.

Check WebSentry configuration settings

By default the unit is configured to use DNS (Domain Name Server) to translate the Seresco domain name to the

appropriate WebSentry IP address. Before software version 4.8.0, domain name www.seresco.net was used. Starting from

version 4.8.0, domain name websentry.seresco.net is used.

If the IP is changing between an IP address and 0.0.0.0, there is a problem with the domain name lookup. In this case you

can try to configure a static IP for the WebSentry server.

Change Use DNS to No and then change the IP address to IP of websentry.seresco.net (currently 97.74.200.218).

Testing Internet access from unit

Unit has a Ping feature that can be used to test that unit can connect to any IP address on the local network as well as to any

IP over Internet.

To use the Ping feature you have to start the unit in Service Mode. From main screen select Main Menu (1) - System (3) -

System Restart (3) and then press Yes (1) to confirm.

When unit starts up you will have a selection menu. Select Service (2).

X-3

Section X - Troubleshooting Issue Date : 2011-09-20

To access the Ping feature, select Main Menu (1) – Service (6) – Network (3) – Ping (1). If asked for a password at Service

selection, enter 813.

To test connection to WebSentry server, make sure IP (selection 1) is set to 97.74.200.218. Press 2 to start Ping request.

The 3rd line shows the current IP address assigned to the unit. The 4th line will either have 4 time values or the text Fail (up

to 4 times). The time values indicate number of milliseconds for Ping message to go to WebSentry server and back.

Testing Internet access and WebSentry access from unit Ethernet cable

A simple test you can do to make sure there is Internet access from the Ethernet cable connected to our unit is to connect

this cable into a laptop and accessing any web site using a web browser.

If unit is configured for static IP, you should configure the laptop with the exact same TCP/IP configuration. How this is

done is not covered in this document.

IMPORTANT! Make sure WiFi connection is disabled when testing Ethernet cable.

A secondary test to ensure you can communicate with the Seresco WebSentry server is to use the Telnet command to

establish a connection to the server.

Open up the Command Prompt window. Enter the command:

telnet 97.74.200.218 1030

You should now see a blank screen with a prompt. Hit any two characters. The text Seresco WebSentry should now be

displayed followed by Connection to host lost. This verifies that you can open up a connection to the port used by the

WebSentry server and that this port is not blocked by any firewall.

If the connection failed it most likely is a firewall issue. Port 1030 must be open for communication or at least for the IP

assigned to the Seresco unit.

Contact Factory

If everything in this document has been tested and everything indicates that the communication should be working, we are

dealing with an unknown fault. Contact Seresco for further advice.

X-4

Issue Date : 2011-09-30 Section Y - Warranty

Warranty

General Policy

This warranty applies to the original equipment owner and is not transferable. Seresco Technologies Inc.

warrants as set forth and for the time periods shown below that it will furnish, through a Seresco Technologies

Inc. authorized installing contractor or service organization, a new or rebuilt part for a factory installed part

which has failed because of defect in workmanship or material.

Warranty Void Unless Registered

Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up Report” is

completed and sent to the factory within one week of initial start-up. This report will also register the

compressor warranty with the compressor manufacturer.

Initial 90-day Warranty

During the first 90 days from initial start-up and prior to the completion of the 24th month from date of

shipment, whichever comes first and subject to prior written approval from the factory, Seresco Technologies

Inc. will provide and/or reimburse the required labour, materials, and shipping and handling costs incurred in

the replacement or repair of a factory installed defective part. Only the labour required to replace the defective

part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not covered under this

warranty.

WebSentry Conditional One Year Extended Labour Warranty

The factory labour warranty shall be extended for a total of 12 months from initial start-up and prior to the

completion of the 24th month from date of shipment, whichever comes first and subject to prior written

approval from the factory. The provided equipment must be connected and communicating to Seresco's

WebSentry online control and monitoring service for the entire term of the warranty extension. Seresco

Technologies Inc. will provide and/or reimburse the required labour, materials, and shipping and handling

costs incurred in the replacement or repair of a factory installed defective part. Only the labour required to

replace the defective part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not

covered under this warranty.

Two Year Parts Warranty

If any factory installed part supplied by Seresco Technologies Inc. fails because of a defect in workmanship or

material prior to the completion of the 24th month from date of shipment, Seresco Technologies Inc. will

Y-1

Section Y - Warranty Issue Date : 2011-09-30

furnish a new or rebuilt part F.O.B. factory. No labour reimbursement will be made for expenses incurred in

making field adjustments or parts replacement outside the Initial 90-day Warranty. Seresco Technologies Inc.

reserves the right to have the defective part returned to the factory in order to determine the warranty

applicability. Parts shipping and handling costs (to and from the factory) are not covered outside of the Initial

90-day Warranty.

Replacement Part Warranty

If a replacement part provided by Seresco Technologies Inc. under this warranty fails due to a material defect

prior to the end of the Two Year Parts Warranty (or the end of the extended warranty period if applicable) or 12

months from date of the replacement part shipment, whichever comes first, Seresco Technologies Inc. will

furnish a new or rebuilt part F.O.B. factory.

Applicability

This warranty is applicable only to products that are purchased and installed in the United States and Canada.

This warranty is NOT applicable to :

1. Products that have become defective or damaged as a result of the use of a contaminated water

circuit or operation at abnormal water temperatures and/or flow rates

2. Parts that wear out due to normal usage, such as air filters, belts and fuses. 2. Refrigerant lost during

the parts warranty will be reimbursed in accordance to the current market price of refrigerant at the

time of repair. Seresco Technologies Inc. will not be responsible for refrigerant lost from the system

due to improperly installed contractor piping to the remote outdoor air cooled condenser.

3. Refrigerant coils that corrode due to improperly balanced pool chemistry or corrosive air quality.

4. Components that have been relocated from their original placement at the factory.

5. Any portion of the system not supplied by Seresco Technologies Inc.

6. Products on which the model and/or serial number plates have been removed or defaced.

7. Products which have become defective or damaged as a result of unauthorized opening of

refrigeration circuit, improper wiring, electrical supply characteristics, poor maintenance, accidents,

transportation, misuse, abuse, fire, flood, alteration and/or misapplication of the product.

8. Products not installed, operated and maintained as per Seresco Technologies Inc. Owner’s Manual.

9. Products on which payment is in default.

Limitations

This warranty is given in lieu of all other warranties. Anything in the warranty notwithstanding, any implied

warranties of fitness for particular purpose and merchantability shall be limited to the duration of the express

warranty. Manufacturer expressly disclaims and excludes any liability for consequential or incidental damage

Y-2

Issue Date : 2011-09-30 Section Y - Warranty

for breach of any express or implied warranty.

Where a jurisdiction does not allow limitations or exclusions in a warranty, the foregoing limitations and

exclusions shall not apply to the extent of the legislation, however, in such case the balance of the above

warranty shall remain in full force and effect.

This warranty gives specific legal rights. Other rights may vary according to local legislation.

Force Majeure

Seresco Technologies Inc. will not be liable for delay or failure to provide warranty service due to government

restrictions or restraints, war, strikes, material shortages, acts of God or other causes beyond Seresco

Technologies Inc. control.

Optional Five Year Compressor Warranty

This extended warranty must be purchased before the shipment of the unit.

Seresco Technologies Inc. will provide a replacement compressor for 60 months from the date of shipment

provided the factory installed compressor fails as a result of manufacturing defect and is returned to the factory

with transportation prepaid. This extended compressor warranty is subject to all the terms of the standard

Seresco Technologies Inc. warranty but applied to the compressor only.

No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,

will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.

Optional Five Year Airside Coil Warranty


Seresco Technologies Inc. will provide a replacement Airside Coil for 60 months from the date of shipment

provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is

subject to all the terms of the standard NE Series warranty but applied to the coil only.



This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2

and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These

Y-3

Section Y - Warranty Issue Date : 2011-09-30

parameters are to be measured and recorded daily and be available for review upon request.

Optional 10 Year Airside Coil Warranty


Seresco Technologies Inc. will provide a replacement Airside Coil for 120 months from the date of shipment

provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is

subject to all the terms of the standard NE Series warranty but applied to the coil only.



This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2

and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These

parameters are to be measured and recorded daily and be available for review upon request.

Optional Five Year Driveline Warranty


Seresco Technologies Inc. will provide a replacement part for the following components:

Supply fan motor

Supply fan motor starter

Exhaust fan motor

Exhaust fan motor starter

Pool water heater solenoid valves & valve coils

Liquid expansion solenoid valves & valve coils

Air-cooled condenser solenoid valves & valve coils

Blowers

Driveline warranty exists for 60 months from the date of shipment provided the factory installed component

fails as a result of manufacturing defect and is returned to the factory with transportation prepaid. This

extended driveline warranty is subject to all the terms of the standard Seresco Technologies Inc. warranty but

applied to the listed parts only.

No charges attributed to the replacement of a component will be allowed unless specifically granted in writing

beforehand by Seresco Technologies Inc.

Y-4

Issue Date : 2011-09-30 Section Z - Annex

Unit Component Specifications

&

Component Service Sheets

Z-1

Rotating Electrical Machines

Totally enclosed fan-cooled (TEFC)three-phase motors with squirrel cage

for low voltage, with antifriction bearings.

Installation InstructionsNEMA - IECW Range

Installation & Maintenance

Introduction

All ac induction motors are designed for long life and

low running costs. Careful installation and mainte-

nance will ensure that you achieve reliable operation

and optimum efficiency. For motors with specific

duties, such as brake motors, single phase motors

and motors installed within hazardous areas, please

refer to your supplier.

Pre-installation requirements

Warning

Handling and lifting of electric motors must only be

undertaken by authorised personnel. Full product

documentation and operating instruction must be

available together with tools and equipment neces-

sary for safe working practice. If there are any safety

concerns, do not install or attempt to operate the

motor. Please contact your supplier for advice or

assistance.

Receipt

Before any motor is accepted on site, it should be

inspected carefully against the following checklist:

a) Check that the description on the

consignment note agrees with your order

specification.

b) Check that the rating, speed etc are in

accordance with your requirements.

c) Check for any damage, rust, dirt, foreign

substance etc. Where an instance of

droppage or loss is evident or suspected, it may

be necessary to unpack the goods to

establish the full extent of the problem.

Wherever possible, damage should be

recorded, photographed and witnessed.

Report any damage to the carriers and

your supplier as soon as possible, quoting

the motor and/or order number and

shipping reference.

d) Check that the direction of rotation, if

specified, is correct. Manually turn the

shaft and check for smooth, quiet rotation.

Electric motors should not be transported

by rail, as vibration from this method of

transport has been known to cause

brinelling of bearings.

Lifting

Eyebolts, lifting lugs and lifting trunnions supplied

with the motor are designed to support only the

weight of the motor, not the weight of the motor and

any ancillary equipment attached to it. Be absolutely

sure that cranes, jacks, slings and lifting beams are

capable of carrying the weight of equipment to be

lifted safely.

Where an eyebolt is provided with the motor, this

should be screwed down until its shoulder is firmly

seated against the face of the stator frame to be lift-

ed. Eyebolts are normally designed for a vertical lift.

For lifting lug or trunnion torques, see table below:

* Lifting lugs secured with bolts and nuts. High ten-

sile socket headed bolts and special square nuts

must be used. Aluminum frame motors should have

eyebolt firmly screwed down (without overtighten-

ing), to ensure that the collar is fully seated.

Where two eyebolts/lifting lugs are used with inclined

loading, the maximum safe working load quoted on

the lifting arrangement must not be exceeded.

Storage

If motors have to be stored before installation, pre-

cautions should be taken to prevent deterioration:

Environment

Depending on the site conditions, it may be neces-

sary to create a suitable stores area to hold the

motor prior to installation. Packing cases are not

waterproof.

Motors should be stored in a dry, vibration free and

clean area at normal ambients (-20°C to 40°C),

unless other arrangements have been agreed.

Where low temperature ambient storage is anticipat-

ed, special precautions should be taken with the

type of grease, no plastic parts etc to ensure trouble-

free start-up.

Motors must be stored away from corrosive or

chemically damaging fumes. Before placing motors

into storage, machined components should be care-

fully inspected. Bearings and shafts are normally

covered with a corrosion resistive barrier. If this

coating is damaged, it should be made good. The

component should be cleaned and the protective

coating reapplied. Under no circumstances should

rust be merely covered over.

Drain holes

Motors of frame size 160 /254T and above have

drain holes fitted with drain plugs as standard.

Alternatively, the drain plugs can be provided loose

in the terminal box if specifically requested.

Bearings

To avoid static indentation, the storage area should

be vibration free. if this is not possible, it is strongly

recommended that the motors be stood on thick

blocks of rubber or other soft material.

Where the exposure to some vibration is unavoid-

able, the shaft should be locked in position to avoid

static indentation of the bearings.

Shafts should be rotated by hand one quarter of a

revolution weekly.

Roller bearings may be fitted with a shaft locking

device. This should be kept in place during storage.

Grease

Factory-fitted bearings use a grease with a recom-

mended shelf life of two years. If stored for a longer

period the grease may need to be replaced*.

Shielded bearings have a storage life of five years

and a further two years operational life following

installation.

*Wash all bearing parts with a non-contaminating

solvent. Lightly pack the bearings with grease apply-

ing a 25% fill by volume into the bearing and hous-

ings. Run the motor on no-load to distribute grease

and reduce losses.

Heaters

Where heaters are fitted, and the storage environ-

ment has wide humidity and temperature variations,

it is strongly recommended they be energised.

Warnings should be placed on the motors to

make operatives aware of the live heaters.

Insulation resistance

During extended storage, a three-monthly insulation

test is recommended to avoid possible lengthy dry-

ing out periods when installing.

The insulation resistance between phases and

between the phase and earth should be checked

and maintained above 10 Megohm.

If a lower reading is measured, use one of the rec-

ommended drying out methods until an acceptable

reading is obtained. If heaters are fitted but not ener-

gised, they should be used in future.

1

Lifting lug bolt torques

63

71

80

90

100L112M

132S/M

160M/L

180M/L

200L

225S225M250S250M280S280M315S315M315L

355S/M/L

-

-

56

143/5T

-182/4T

213/5T

254/6T

284/6T

324T

326T364T365T404T405T444T445T504Z505Z

585/6/7Z

Type

-

-

-

-

-

M12*

M12*

M12*

M16*

M10*

M10*

M10*

M10*

M16*

M16*

M16*

M16*

M20*

M20*

M20*

-

-

-

-

-

-

-

-

-

52

52

52

52

220

220

220

220

400

400

400

-

-

-

-

-

-

-

-

-

38

38

38

38

162

162

162

162

295

295

295

Metric NEMA/CSA

Boltdia* Nm Lbf.FT

Torque


Installation

It is the users or certified electricians reponsibil-

ity to ensure correct earthing and protection in

accordance with applicable national and local

requirements and standards.

Location

Motors must be installed with adequate access for

routine maintenance. A minimum of 0.75m of work-

ing space around the motor is recommended, partic-

ular attention at the fan inlet (50mm) is necessary to

facilitate airflow. Ensure that there is sufficient free

area in front of the air intake.

Where several motors are installed in close proximi-

ty, care must be taken to ensure that there is no re-

circulation of exhausted warm air, as this will reduce

the effectiveness of the cooling system.

Foundations must be solid, rigid, level and where

possible free from any external vibration.

Mechanical

Drain holes

Prior to installation, remove drain plugs if fitted. If

any water has accumulated, the integrity of all gas-

kets, sealants etc should be checked. Drain plugs

should be put back into place after draining.

Alignment

When the application calls for direct coupling, the

shafts must be correctly aligned in all three planes.

Bad alignment can be a major source of noise and

vibration.

Allowance must be made for shaft end-float and

thermal expansion in both axial and vertical planes.

It is preferable to use flexible drive couplings.

Motors fitted with angular contact or duplex bear-

ings, must always be run loaded.

Slide rails and slide bases

Slide rails and bases are available for all motors in

the product range to provide adjustable mounting.

Fabricated steel rails and bases are the standard

offer as they are suitable for all relevant mounting

arrangements.

Installation:

1) They must be installed on a flat surface.

2) They must have a secure location.

3) Drive and driven shaft must be parallel.

Electrical connection

Connection diagrams

The connection diagram is shown on the leaflet

enclosed in the motor terminal box or diagram inside

the terminal box lid and provides supply details and

the required winding connection. The cables used

should be capable of carrying the full load current of

the motor (see motor nameplate), without

overheating or undue voltage drop.

Cable terminations

All cable terminations should be tightly secured.

Mains lead terminal lugs should be in face-to-face

contact with the motor lead lugs and securing nuts

and lockwashers screwed firmly over the connection.

There should be no nuts or lockwashers fitted

between the mains and motor lugs.

Wiring should be carried out or checked by a quali-

fied electrician and equipment must be earthed in

accordance with current regulations. The equipment

must be correctly fused and isolated. All covers must

be in position prior to running.

All fixing bolts and electrical connections should be

checked and tightened if necessary after 100-200

hours of operation.

Warning

Isolate power supply to motor before commencing

any routine cleaning or maintenance work.

Drying out procedures

It is preferable to dismantle the motor to the point

where the rotor is removed. This is not essential but

the drying out process will take longer in the assem-

bled state. The temperature of the windings and the

insulation resistance should be monitored at regular

intervals. On initial application of heat, the insulation

resistance will drop quickly and then start to rise

slowly until level. On discontinuation of the drying

process, a further rise in resistance will occur.

There are several methods which can be used:

1) Place the motor in a warm (typically 40°C),

dry airstream (fan or convector heater) or

in a warm oven with a temperature not

exceeding 80°C. This method is preferred if the

motor is dismantled.

2) Connect the motor to a low voltage* three

phase supply and inject a current not

exceeding 50% of the full load current into

the stator winding (*approximately 10% of

the line voltage). If this is carried out on an

assembled motor, it is possible though

unlikely that the motor will turn. If so, the

rotor should be locked in position.

3) Connect two phases in parallel, and the

third in series. Apply a low voltage ac or dc

suply up to a maximum of 50% of full load

current. The stator winding temperature must not

be allowed to exceed 80°C. In practice, the frame

should not be hot to the touch, to guard against

internal overheating and consequent damage to

the insulation.

4) Where heaters are fitted, these can be

energised.

Supply

It is important that a motor is operated within the lim-

its of its design voltage and frequency.

Standard motors will operate without damage on any

voltage within the range of the nameplate voltage.

The supply cables must be capable of carrying the

full load current of the motor (see motor nameplate)

without overheating or excessive voltage drop under

starting conditions.

Grounding

All motors fitted with an grounding terminal, in or

adjacent to the terminal box to enable connection to

an effective earthing bond. The terminal is designed

for connecting the correct size of copper earth con-

nector. If a different material is to be used, please

refer to your supplier.

An earthing bond should not be terminated

under the motor fixture bolts or terminal cover

screws. The ground lead could be overlooked

on reconnection after maintenance.

Auxiliary electrical items

Where auxiliaries are fitted, the characteristics

should be checked. Example: RTDs (Resistance

Temperature Detectors), should have their resistanc-

es checked against manufacturer’s figures.

Auxiliaries should be checked for continuity prior to

connection to the control circuitry.

Do not apply more than 6V across the thermistor for

continuity check.

Control gear

Ensure all control gear and associated metering/pro-

tection circuits have been checked fully.

It is imperative that any overload trip and emer-

gency shutdown circuits are working correctly

before the motor is energised. All covers must

be in position.

Where a motor is fitted with a separately driven fan

unit, the interlocks and thermal overload protection

circuits must be operative.

Rotation

Before coupling the motor to the drive, run the motor

briefly to check rotation.

All covers must be in place.

To reverse the direction of rotation, interchange any

two incoming supply leads.

2


Starting

Motors are rated by the output required, the number

of starts per hour, the load curve/inertia and environ-

mental considerations.

Operating outside the contractual parameters may

thermally overload the motor, eg too many starts per

hour, or mechanically stress components, eg over-

speeding.

Refer to starter literature for methods of start

and safety precautions to be taken.

Running

After one hour of running, check the general vibra-

tion levels. If these are excessive, check alignment

(and belt tensioning if belt driven).

Some initial bearing noise may be present during the

running-in period. This is normal because the grease

has to settle down within the bearing. This noise

should disappear after a few hours of operation.

Check that the motor runs up smoothly and within

the permitted run-up time. Note that repeated start-

ing in quick succession may lead to a thermal over-

load of the motor.

Fitting couplings and alignment

Extreme care must be exercised in lining up cou-

plings as misalignment can be detrimental to the

shaft and bearings. For direct drives, we recommend

that flexible couplings are used. Please ensure that

the alignment instructions given by the coupling

manufacturer are followed.

Do not at any time force in the fitting of couplings,

pulleys etc. All motors are provided with a threaded

hole in the drive end shaft to assist fitting and

removal. A bolt should be used in this hole and a nut

with a large washer used to press the coupling or

pulley against the shoulder of the shaft. Care must

also be taken to ensure that the motor bearings are

not subjected to end-thrust caused by the two halves

of the couplings being squeezed too tightly together.

Please ensure that all couplings, belts, pulleys etc

are properly and permanently guarded against acci-

dental contact while the motor is running.

Care should be taken to ensure fixing bolts are cor-

rectly tightened.

Belts drives

Please ensure that the V-belts are of the same man-

ufacture and have the same dimensions. Also

ensure that the belts are correctly tensioned in

accordance with the manufacturer’s recommenda-

tions. If the V-belts are not tensioned correctly, it can

cause belt and pulley wear and/or shaft and bearing

damage. When replacing belts, it is recommended

that all belts be replaced at the same time. It is also

not generally recommended to use two pole motors

for belt drive applications.

Motor modifications

Warning

All modifications should be carried out by a trained

operative. Do not work under suspended load and

use correct lifting equipment.

Changing terminal box position

(on multi-mount motors)

1) Lift motor, using eyebolt or lifting lugs

provided

2) Slacken / remove the foot fixing bolts

on one foot

3) Pull the foot away from the frame

4) Repeat stages 2 to 3 on the other foot

5) Lower the motor onto two pieces of

timber

6) Remove the eyebolt or lifting lugs

7) Rotate the motor until the terminal box is

in the correct position.

8) Refit the eyebolt or lifting lugs on the

machined pads at the top of the motor

(diagonally opposite corners for lifting

lugs). Ensure that lifting lugs are in

contact with all machined faces and that

the correct bolts and nuts are used.

Tighten the bolts to the correct torque.

9) Remove fan cover

10) Remove the endshield bolts at both ends

of the motor.

11) Slacken drive end bearing cap or

clamping screws to allow endshield

spigot to disengage.

12) If grease nipples are fitted, disengage

both endshield spigots and rotate the

endshields through 90° until the grease

nipples are at the top, or the desired

position.

13) Refit endshield bolts and tighten to the

correct torque.

14) Retighten the bearing cap screws at the

drive end, replacing the washers

under the bolt heads. Tighten screws to

the correct torque.

15) Lift motor using the eyebolt hooks or the

lifting lugs.

16) Strip paint from the pads where the feet

are to be fitted and apply a thin film of

grease for corrosion protection on bare

surfaces.

17) Refit the feet in the reverse order of

dismantling (steps 2 and 3).

18) Ensure the feet are fully in contact with

the machined faces. Tighten all bolts to

the correct torque.

19) Repeat stages 18 to 19 on the other foot.

20) Prime and paint all machined surfaces

left exposed by the changes.

21) Refit fan cover with the greasing hole in

the correct position (if in doubt, contact

your supplier).

Note:

If drain holes were present they may now be

positioned at the top of the motor.

Bearings, grease, bearing change

Grease

Regreasable bearings are pre-packed with a lithium

or lithium complex based grease.

Other lithium based greases of a similar consistency

would be compatible. See table below for some

alternatives:

Where a special grease has been supplied, this will

be indicated on the motor nameplate.

Regreasing

Standard regreasing facilities, where provided, are

situated on the periphery of the drive end and non-

drive endshields.

Grease relief is via a:

a) Diaphragm relief valve.

b) Rotating grease relief flinger.

c) Plugged grease chute.

For motors with open bearings and without grease

relief facilities, the old grease must be cleaned out

from time to time by removing the bearing cap

and/or endshield. The bearing and housing must

then be re-packed with grease and reassembled. Do

not overfill the bearing housing - it should not be

more than a quarter full of grease after reassembly.

Motors with sealed for life bearings usually employ a

polyurea EA6 grease. These should be fitted with

new bearings based on the bearing life stated in the

product catalogue.

An overgreased bearing will cause overheating of

the bearing with the possible escape of the grease,

loss of lubrication qualities, leading to ultimate bear-

ing failure.

Grease Reference Manufacturer

Alternative lithium complex greases

EnergreaseCastrolLuplexUnirexSovereignMobilgreaseLiplexHytexRetinaxLGHT3

LC2LMXM2

N2LSHP

EP2EP2LX-

BPCastrolCentury

EssoGulf

Mobil

ShellTexacoShellSKF

3


Lubrication procedure

The following procedure should be adopted:

1) Wipe clean the grease gun fitting and the

regions around the motor grease fittings.

2) Remove the grease relief plug if fitted.

Some motors will have one way grease

valves which should be left in place.

3) Add a small quantity of grease,

approximately 4 to 10 shots depending

on frame size.

4) Allow motor to run for approximately 10

minutes in order that excess grease may

be expelled before refitting the relief plug.

Bearings fitted with rotating grease relief

or through grease valves will relieve

automatically. Grease may not be

expelled from the motor during filling due to

internal cavities/pipes filling or relief via seals.

5) On initial start up or after relubrication,

‘bearing noise’ may result from the new

grease moving around the bearing. This

noise is normal and will disappear after a

few hours of running.

Bearing change

When fitting new bearings, the parts should be

lightly lubricated with grease.

The bearing should be driven onto the shaft by pres-

sure on the inner race only using a short length of

tube placed over the motor shaft.

On larger motors, it is easier to raise the tempera-

ture of the bearing using an oil bath, oven or induc-

tion heating. The temperature must be controlled to

120°C maximum. Suitable handling precautions

should be taken.

The bearing should then be quickly slipped into

place, ensuring that the bearing is in contact with the

shaft shoulder.

When cool, ensure that the bearing is clean and

charge the bearing with the recommended quantity

of grease. Bearings and housings should be approx-

imately a quarter full.

Fitting flange adaptor (where applicable)

1) If required, remove foot as detailed in

terminal box position change.

2) If required, reposition terminal box and

lifting lugs.

3) Clean paint off the drive end endshield

spigot and remove all the plastic bolt-hole

cover caps. Apply a film of non-setting

jointing compound on bare machined

surfaces for sealing and corrosion

protection.

4) Fit flange ring onto spigot positioning fixing holes,

where applicable, to provide either BS or DIN

flange hole positions.

5) Bolt ring into position, using the same

size socket head bolts as used on the feet.

These are supplied with the flange ring kit.

6) Tighten the bolts to correct torque.

Change from ball/ball to roller/ball construction

200 - 355 ~ 324T - 586 frame

1) Isolate motor before commencing work.

2) Remove fan cover and fan.

3) Remove bearing cap screws.

4) Remove endshield at both ends.

5) Remove bearing circlips at both ends.

6) Remove preload washer at non-drive end.

7) Replace drive end ball bearing with new

roller bearing and refit circlip.

8) Remove non-drive end ball bearing and

inner bearing cap.

9) Fit new non-drive end inner bearing cap

with shallow recess (identical to existing

drive end inner bearing cap.

10) Examine existing non-drive end ball

bearing and either refit or replace.

11) Refit non-drive end bearing circlip.

12) Re-pack bearings with new grease in

accordance with recommendations.

13) Ensure the lip on both oilseals is

greased.

14) Refit both endshields and check that:

a) spacer O/D is the same

as the bearing O/D

b) bearing spacer supplied is fitted into

the non-drive end and endshield

bearing recess

c) slots in inner bearing caps are

aligned with endshield grease chutes

d) correct location for bearing cap by

the use of a stud

e) bolts are torqued up to

recommended figures

Maintenance

Ongoing maintenance

Induction motors by their very nature require very lit-

tle maintenance. However a regular regime of

inspection is recommended to ensure minor prob-

lems do not escalate to breakdowns. Typical inter-

vals would be 2000 hours of operation or 3 months,

whichever is the sooner.

Checklist:

• No visible damage, ie fans cracked, fan

cowls bent, foot cracked etc

• No accumulation of dust or fibres on the

frame or around the fan inlet

• No significant corrosion of the lifting

lugs/eyebolts

• No excessive vibration

• No loose fasteners

• Cables and earth are sound

• Sealing of the motor and gland plate in

good condition

• Insulation resistance adequate, imperative this

is checked after a prolonged shut-down

• Regrease required, particularly large

output 2 pole motors

• Bearing condition

Note:

Smoke extraction motors or motors on safety

critical applications should be rewound, to the

original specification, after 40,000 hours of oper-

ation. If variable speed employing unipolar

switching the period is reduced to 30,000 hours

and reduced again to 20,000 hours for bipolar

switching. In all cases refer to your supplier.

Periodic maintenance

Remove the fan cover and the fan which is keyed,

clamped, pinned or knurl located to the shaft exten-

sion. Loosen and remove bearing cover screws and

endshield bolts/studs. The endshields should then

be eased off their spigots.

The rotor can now be carefully withdrawn from the

stator, taking care not to damage the stator bore

and both stator and rotor windings.

Having dismantled the motor, maintenance can be

carried out to remove all dirt. For this purpose, the

use of an air line supplying dry compressed air

under comparatively low pressure is best, as a high

velocity airstream can force dirt into the spaces

between the windings and insulation etc. Grease-

removing solvents should only be used very sparing-

ly to avoid damage to impregnating varnish or insu-

lation.

Motors should be re-assembled in the reverse order

from dismantling, remembering to ease endshields

onto bearings and spigots. Do not use force. On re-

assembly oilseals to mating faces should be lubricat-

ed. If oilseals are worn or damaged during disman-

tling then they should be replaced before continuing.

Before starting the motor, check that the rotor

revolves freely. Ensure that the electrical connec-

tions are correct and terminal nuts tight (see section

- Electrical Connection).

Spares and repairs

When ordering spares, it is important to state the

motor serial number to ensure that the correct

spares will be supplied.

Metric NEMARegreasing

facility

Standard regreasing facilities

63-180*

200-355

56-286

324-587

on request

standard

Type

* Bearings are double shielded and pre-packed with grease for life

4


Notes

Fixing bolts, nuts, studs, screws, spacers or washers

are not included with these parts and, if required,

should be clearly specified on the order in addition to

the part description number. The fixing duty and part

description reference number for which they are

required, should also be clearly stated.

Contact must be made prior to any remedial action

being taken under warrantee

Please quote the motor serial number in all such

cases with full details of the problem.

Exploded view of a typical standard ac motor

12

3

45

6

78

9

1011

12

1314

15

Ref Part description

Flange endshieldEndshield fixing bolt

Drive end endshield

Rotor assemblyFlinger (when fitted)

Drive end oil seal (when fitted)

Preload washerDrive end bearing

Stator assembly with or without feet

Eyebolt (when fitted) or dual lifting lugBearing retention circlip

Non-drive end bearing

Non-drive end endshieldEndshield fixing bolt

Bearing circlip

16

1718

19

2021

22

2324

25

2627

28

2930

Ref Part description

Non-drive end oilseal (when fitted)

FanFan circlip

Fan cover

Fan cover screw and washerFoot fixing bolts and washer (where applicable)

Feet

Terminal board (when fitted)Terminal box to frame gasket

Terminal box

Internal earth terminalTerminal box lid gasket

Terminal box lid

Pad mounting bracketFace endshield

5

Bearing Information

63

7180M

90S/L

100L

112M

132S/M

160M/L180M/L

200LX

225S

225M

250ME

280SE

280ME

315SE

315ME

315M

315L

355S/M/L

Bearing references and oil seals for horizontally-mounted motors only

European

63

7180M

90S/L

100L

112M

132S/M

160M/L180M/L

200LX

225S

225M

250S

250M

280S

280M

315S

315M

315L

355S/M/L

BS

All

All

All

All

All

All

All

All

All

All

All

All

2

4 up

2

4 up

2

4 up

2

4 up

2

4 up

2

4 up

2

4 up

2

4 up

Polarity

Bearings(1)

Drive end Non-drive end

Oil seals(2)

62022Z

60032Z

62042Z

62052Z

62062Z

62062Z

62082Z

63092Z

63102Z

6312

6313

6314

6314

6316

6314

6318

6314

6318

6316

6319

6316

6319

6316

6319

6316

6319

N316

N324

62022Z

60032Z

60032Z

62032Z

62052Z

62052Z

63052Z

63072Z

63082Z

6312

6313

6314

6314

6316

6314

6318

6314

6318

6316

6319

6316

6319

6316

6319

6316

6319

6316

6324

15 x 24 x 5(3)

17 x 28 x 6(3)

20 x 30 x 7(3)

25 x 35 x 7(3)

30 x 42 x 7(3)

30 x 42 x 7(3)

40 x 52 x 7(3)

45 x 60 x 8(3)

50 x 65 x 8(3)

60 x 80 x 8(3)

65 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

80 x 110 x 10(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

75 x 100 x 10(4)

115 x 145 x 14(3)

Drive end

15 x 24 x 5(3)

17 x 28 x 6(3)

15 x 24 x 5(3)

17 x 28 x 6(3)

25 x 37 x 7(3)

25 x 37 x 7(3)

25 x 37 x 7(3)

35 x 47 x 7(3)

40 x 52 x 7(3)

60 x 80 x 8(3)

65 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

80 x 110 x 10(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

75 x 100 x 10(4)

115 x 145 x 14(3)

Non-drive end

(1) Frame sizes 80 and 90 have bearings with CN clearances, frame sizes 100 to 355 have bearings with C3 clearance ‘medium’ series(2) Sizes given are in mm, and represent bore x outside diameter x widthMaterial: (3) Nitrile rubber (4) Silicon rubber

IEC Type

Bearing references and oil seals for horizontally-mounted motors only

56143/5T

182/4T213/5T

254/6T

284/6T

324T326T

364T

365T

404/5T

444/7T

504/5

Frame

All

All

All

All

All

All

All

All

All

2

4 up

2

4 up

2

4 up

2

4 up

Polarity

Bearings(1)

Non-drive end

Oil seals(2)

62042Z

62052Z

62062Z

62082Z

63092Z

63102Z

6312

6313

6314

6314

6316

6314

6318

6316

6319

6316

6319

60032Z

62032Z

62052Z

63052Z

63072Z

63082Z

6312

6313

6314

6314

6316

6314

6318

6316

6319

6316

6319

15 x 24 x 5(3)

17 x 28 x 6(3)

30 x 42 x 7(3)

40 x 52 x 7(3)

45 x 60 x 8(3)

50 x 65 x 8(3)

60 x 80 x 8(3)

65 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

90 x 120 x 12(3)

90 x 120 x 12(3)

Drive end

15 x 24 x 5(3)

17 x 28 x 6(3)

25 x 37 x 7(3)

25 x 37 x 7(3)

35 x 47 x 7(3)

40 x 52 x 7(3)

60 x 80 x 8(3)

65 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

70 x 90 x 10(4)

90 x 120 x 12(3)

70 x 90 x 10(4)

90 x 120 x 12(3)

90 x 120 x 12(3)

90 x 120 x 12(3)

Non-drive end

(1) Frame sizes 56 to143/5T have bearings with CN clearances, frame sizes 182T to 505 have bearings with C3 clearance ‘medium’ series

(2) Sizes given are in mm, and represent bore x outside diameter x widthMaterial: (3) Nitrile rubber (4) Silicon rubber

NEMA Type

Drive end

6

Connection Diagrams - IEC Frames

7

Connect ion Diagrams - NEMA

8

Fault Finding - Three Phase Induction Motors

Motor will not start

Supply or starter trips out atstart

Motor starts but has no torque.Motor does not reach full speedor takes a long time to accelerate

Motor overheating

No load amps in excess of fullload amps.

1. Fault with supply.

2. Motor or load locked up.

3. Wrong connection in controlcircuit.

1. Wrong or loose connections.

2. Motor overloaded.

3. Inertia of load too high.

4. Low voltage due to volt dropin cables.

5. Overload or circuit breakerincorrectly set or sized.

1. Incorrect connection.

2. Delta wound motor connected in star.

3. Star/Delta starter staying instar.

4. Inertia of load too high.


6. Low voltage due to drop incables.


2. Ineffective cooling.Temperature of air.Look for build up of dirt

3. Excessiive ambient.

4. Wrong connections.

5. Delta wound motor in star.

6. Motor ‘Single Phasing”.

7. Wrong voltage or frequency.

8. Supply voltage unbalanced.

1. Incorrect connection.

2. Star wound motor connected Delta.

3. Voltage in excess of nameplate.

4. Motor supplied for a different voltage or frequency.

1. Check for correct voltage atmotor terminals.2. Make sure motor and loadare free to turn.3. Check to ensure contactorsoperate.

1. Check all lugs are properlycrimped or soldered, and connections are tight.2. Check load performancedata against motor performance data.3. Measure voltage at motorterminals while motor starting.4. Check settings of overloadand circuit breaker and allowfor starting current.

1. Check connection diagramand nameplate data.2. Check load performancedata against motor performance data.3. Measure voltage at motorterminals while motor starting.

1. Check load performancedata.2. Check fan and air flow.

3. Check connection diagramand nameplate data.4. Check volts and amps on allthree phases.5. Check nameplate

6. Check phase to phase voltage accurately.

1&2. Check connection diagram

3. Measure voltage at motorterminals.

4. Compare supply voltage andfrequency to nameplate.

1.. Fit new fuses, reset circuitbreakers, etc.2. Remove clamps, locks etc.

3. Sort out control circuit.

1. Fix up connections.

2. Change motor for correctsize.

3. Change cables for correctsize.4. Correct setting of overloador breaker or change.

1. Sort out and correct connections.2. Check timer and startercontrol circuit.

3. Change motor for correctsize.

4. Change cables for correctsize.

1. Fix problem with load or fit alarger motor.2. Clean motor. Sort out cool-ing of air temp. and flow.

3. Sort out connections.

4. Restore supply to all phases

5. Correct voltage or frequency

6. Balance supply or acceptunbalance

1&2. Sort out and correct connections at motor terminals.

3. Connect supply voltage.

4. Change motor for correctvoltage and frequency.

9

Fault Finding - Three Phase Induction Motors

Mechanical noise or vibration.Noisy bearings. Bearingsoverheating

Motor amps in excess of nameplate full load amps onload.

Excessive electrical noise

Unbalanced amps in differentphases when motor loaded

Motor runs in wrong direction

1. Thrust from load ormisalignment..

2. Damaged bearings, toomuch grease, no grease, or foreign matter in grease.

3. Rotor pulling or foreign matter in air gap.

4. Out of balance load, coupling or pulley.

5. Excessive belt pull.

6. Motor foundations not ridgid

1. Motor overloaded

2. Low voltage supply

3. Wrong voltage and frequency.


5. Motor “Single Phasing”.

6. Supply voltage unbalanced

7. Motor speed not matched toload.1. Wrong connections

2. Wrong voltage.

3. Motor “Single Phasing”

1. Unbalanced power supply.


1. Check gaps between cou-pling halves and alignment.

2&3. Turn shaft slowly by handand feel for roughness or stiffness. Check for bent shaftor fan rubbing.

4. Run motor disconnectedfrom load and then with pulleyor coupling removed.5. Run motor without belts.

6. Check design and construction foundations.performance data.

1. Check load and performance data.2. Measure voltage at motorterminals.3. Check nameplate data.

4. Check nameplate data..

5&6 Check volts and amps inall three phases.

7. Measure motor speed andcheck load requirements.1. Check connections.

2. Check voltage with nameplate.3. Check volts and amps on allthree phases.1. Measure phase to phase voltage accurately.

1. Watch shaft rotation.

1. Re-align couplings.

2&3. Clean bearing housing,change bearings and repackwith fresh grease.

4. Fix up out of balance items.

5. Loosen belt tension.

6. Increase strength of foundations.

1. Fix problem with load or fitlarger motor.2. Fix problem, maybe withlarger cables.3. Correct voltage or frequency

4. Sort out and correct.

5&6 Resore balanced supplyto all three phases.

7. Change motor for correctmotor speed.1. Fix connections.

2. Correct voltage.

3. Restore supply to all phases

1. Balance supply or acceptunbalance

1. Swap any two phases ofsupply.

10

Brook Crompton264 Attwell DriveToronto, Ontario M9W 5B2Tel: 416 675-3844Fax: 416 675-6885Internet: www.brookcromptonna.com

Printed in Canada15/09/04 - 2004.W.OI Issue 1

© Copyright 2002. Brook Crompton. All rights reserved

CALL TOLL FREE - NORTH AMERICA:

1-800-463-89171-800-463-8917OROR

1-800-668-67791-800-668-6779FAX:

416-675-6885847-253-9880

www.brookcromptonna.com

Customer Service

Quebec only:1-888-668-9843

Fax:514-636-4253

Every care has been taken to ensure the accuracy

of the information contained in this publication, but,

due to a policy of continuous development and

improvement the right is reserved to supply

products which may differ slightly from those

illustrated and described in this publication

Issue Date : 2011-09-30 Z - Electric Heaters

Electric Space Heaters

Electric space heaters can be mounted in one of two ways. Unit-mounted heaters are mounted inside the unit

or on the supply air opening. Remotely mounted heaters are mounted in the duct-work and are not supplied by

Seresco Technologies Inc. Electric heaters are offered in single or dual point power connection options. Single

point power means that a single power line is feeding both the electric heater and the unit. Power is brought to

the a power distributor block in the heater from which the unit is powered. This configuration is standard for

unit-mounted residential installations. A dual point power configuration means that the unit and electric heater

are powered from different sources. This is standard for larger installations. Refer to the unit nomenclature

located on the label to see which configuration is used for your unit.

The heater is controlled by an external signal, typically either dry contact, 24VAC power or 0-10 VDC signal,

but this may vary depending on the installation. Each heater is equipped with two bi-metal thermal switches to

protect heating elements from overheating (See Wiring Diagram). During installation, connection or servicing

exercise caution. Refer to local electrical codes and manufacturer's instructions when working with electric

heaters.

Staged Electric Heaters

Electric heaters can come in either single stage or two stage configurations. Single stage electric heaters energize

an external (closed contact) electric heater contactor, providing full output. These heaters are typically used for

small kW applications. Two stage electric heaters split the signal into two separate contacts which each

energize separate stage contactors. This gives better control over heater output (i.e. 50% or 100%) based on

temperature requirements.

Modulating Electric Heaters

Modulating electric heaters use both the modulating (SCR) and the fixed step controller to ensure precise

temperature control and high efficiency. Heater total output is divided between up to nine stages, including an

SCR modulating stage. The modulating heating stage, usually 25% larger than the other heating stages, is

proportionally controlled by CRISTAL CONTROLS SCR and the other heating stages are controlled by the

electronic step controller.

Based on an external control signal (usually 0 – 10 VDC), the step controller activates step controlled stages one

after another as needed. The SCR stage automatically fills the gaps between step controlled stages providing

fully proportional control over the heaters entire kW range.

1

Z - Electric Heaters Issue Date : 2011-09-30

Figure 1 : Single Phase 2 Stage Electric Heater

Figure 2 : Three Phase 2 Stage Electric Heater

2


Figure 3 : Modulating Electric Heater

3


Technical Sheet – Steps Controller

Models: CCE-4 : 4 ON/OFF stages + 1 SCR stage

CCE-8 : 8 ON/OFF stages + 1 SCR stage

Power supply 24 Vac, 1 VA

Outputs (ON-OFF stages) 1 Amp max., 120Vac max.

Zero SCR Adjustable

Span SCR Adjustable

Span input Adjustable (Min 2 ON/OFF + 1 SCR)

Input signal 0-135 Ohms, 0-10 Vdc, 0-5 Vdc,

4@20mA

Operation temperature - 40 to +160 (- 40 @ +72 )

Storage temperature - 40 to +160 (- 40 @ +72 )

Dimensions : CCE-4 210 mm X 56 mm X 30 mm8 1/4” X 2 3/16’’ X 1 3/16’’

Dimensions : CCE-8 210 mm X 108 mm X 30 mm8 1/4” X 4 1/4” X 1 3/16”

Figure 4 : CCE Control Wiring

4


Control signal:

0 – 10 VDC: put a jumper between pins 4 and 5,

bring control signal to pins 2 and 6 (pin 2 must be a ground, DCC, pin 6 is a 0-10 VDC signal)

4-20 mA: put a jumper between pins 2 and 5,

bring control signal to pins 2 and 5 (pin 2 must be a ground)

24 VAC power supply:

24 power: Pin 8

24 com: Pin 1 (pin 1 must be grounded)

Stages control:

SCR (modulating): Pins 9 and 10 (see diagram)

ON/OFF (steps): Respective pairs 11-12, 13-14 etc

5


Adjustment Procedure

Note that CCE step controllers are adjusted upon installation. If it is determined that an adjustment is necessary,

follow the following procedure.

Potentiometers' functions:

“SPAN D'ENTREE” - Used to adjust/enable number of stages/steps

“SPAN DU SCR” - Used to adjust the SCR's span between two stages. To adjust, turn clockwise

“ZERO DU SCR” - Used to set the starting (zero) point of the SCR

1. Set the step controller to the desired mode (0-10 VDC or 4-20mA).

2. Set the control signal to 50%.

3. Adjust the “Span d’entrée” until half the stages are lit.

4. Set the control signal at 100% and ensure all stages are lit, readjusting the “Span d’entrée” if needed.

5. If adjustments were necessary at point 4, repeat points 3 and 4 until no further adjustment is needed.

6. Set the control signal at 50% and, if necessary, adjust the “Zéro du SCR” to obtain a 50% modulation output.

7. Set the control signal at 0% and make sure that all stages and the modulating output are off. If the modulating

output does not turn off decrease “Span du SCR” and bring back the control signal to 50%. If needed adjust the

“Zéro du SCR” to obtain a 50% modulation output.

8. Set the control signal at 100% and make sure all stages and the modulating output are open (without modulation).

If the modulating output is still modulating, increase the “Span du SCR” , bring back the control signal to 50% and

if needed, re-adjust the “Zéro du scr” to obtain a 50% modulation on the modulating output.

9. If adjustments were necessary at point 8, repeat points 7 and 8 until no further adjustment is required.

10. Finally, set the control signal at 0% and make sure all stages are off. Set the control signal at 100% and make

sure all stages gradually turn on. Between each stage, the modulating output should be modulating from 0% to

100%. Also make sure that the modulating output does not take too long to begin after a stage kicked in or reaches

the 100% too quickly before the next stage kicks in. In the event that the modulating output is not acting

progressively (too long to begin or reaches 100% too quickly), increase the “Span du SCR” and repeat procedure

from point 6.

6

Perfection is Our Drive

E

G

F

A

C

B

G

B

C

A

F

SIZE

A: Length B:HEIGHT C:LENGTH

D:DEPTH (NOT SHOWN)

F:HEIGHT G:HEIGHT

FNPT FNPT FNPT FNPT FNPT

0.5 2.6 2.9 6.5 3.0 7.5 2.4

0.75 2.8 2.9 6.6 3.0 7.5 2.0

1 2.8 3.3 6.6 3.0 7.5 2.0

1 3.0 3.4 6.7 3.0 8.0 2.6

1 4.2 3.6 7.3 3.0 9.0 3.3

1.25 3.0 3.4 6.7 3.0 8.0 2.5

1.25 3.6 3.6 7.0 3.0 8.6 2.8

1.5 3.5 3.6 7.0 3.0 8.8 2.8

1.5 4.0 4.1 7.2 3.0 9.6 3.3

2 4.0 4.1 7.2 3.0 9.7 3.3

2 5.0 4.5 7.7 3.0 10.8 3.8

2.5 5.3 4.8 7.8 3.0 11.0 4.0

Dimensions (nominal) (measured in inches unless noted)

Ball Valve Product Data

Technical Data/Submittal

Three-way Threaded Equal Percentage Ball Valves with Fail-safe Actuators NEMA 4

Valve Specifications

Static Pressure/Temp: 360 PSI / 250°F (600 WOG)

Service: Chilled water, hot water, up to 50% Glycol

Flow Characterizing Disc: Glass Filled Polymer

Body Material: Forged Brass ASTM B283

End Connections: Brass NPT

Stem: Brass

Stem Seals: EPDM O-Rings

Ball: Nickel-plated brass

Ball Seals: Teflon Seals with EPDM O-Rings

Angle of Rotation: 0–90°

©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 07-11/01/07-15

Three-way valve coil and bypass streams flow simultaneously through the ball. Bypass Cv is always 80% of coil Cv so there is always enough pressure drop in bypass mode. Three-way over-flow problems are eliminated.

Flow characterizing disc:

Equal percentage flow mirrors equal percentage coil characteristic.

Molded from GE NORYL, a blend of a polymide with reinforced modified polymer PPE for retention of mechanical properties, chemical resistance, and dimensional stability.

Because the disc is press fit into the ball where flow exits, the valve is able to modulate where differential pressure is over 160 psi without affecting the disc.

Tapered shape means the back of the disc is too large to be forced through the ball’s port.

Good chemical resistance to: alcohol, alkalis (base), cooling and heating system liquids (ethylene and propylene glycol), chlorinated water, detergents/cleaners. Poor chemical resistance to acids (high concentration), hydrocarbons, ketones, phenol.


3-Way ValveCv

(1∆P)Full Port

Size Close-off

Fail-safe Actuator, 24 VAC

On/off Floating

Point 0/2-10 VDC

BSP-35A1U BSP-35F1U BSP-35P1U

Please check valve/actuator choice below

B3B.5-0.33N 0.33 1/2” 50 psiB3B.5-0.59N 0.59 1/2” 50 psiB3B.5-1.0N 1.0 1/2” 50 psiB3B.5-2.4N 2.4 1/2” 50 psiB3B.5-4.3N 4.3 1/2” 50 psiB3B.5-8.0N 8.0 1/2” 50 psi

B3B.75-0.40N 0.40 3/4” 50 psiB3B.75-0.66N 0.66 3/4” 50 psiB3B.75-1.4N 1.3 3/4” 50 psiB3B.75-2.4N 2.4 3/4” 50 psiB3B.75-3.8N 3.8 3/4” 50 psiB3B.75-11N 11 X 3/4” 50 psi

B3B1-0.40N 0.40 1” 50 psiB3B1-0.65N 0.65 1” 50 psiB3B1-1.3N 1.3 1” 50 psiB3B1-2.3N 2.3 1” 50 psiB3B1-3.5N 3.5 1” 50 psiB3B1-10N 10 1” 50 psiB3B1-8.6N 8.6 1” 50 psiB3B1-22.3N 22.3 1” 50 psiB3B1-14.9N 14.9 1” 50 psiB3B1-4.5N 4.5 1” 50 psiB3B1-30.8N 30.8 1” 50 psi

B3B1.25-19.4N 19.4 X 1-1/4” 40 psiB3B1.25-12.7N 12.7 1-1/4” 40 psiB3B1.25-4.1N 4.1 1-1/4” 40 psiB3B1.25-8.7N 8.7 1-1/4” 40 psiB3B1.25-34.1N 34.1 X 1-1/4” 40 psiB3B1.25-26.8N 26.8 1-1/4” 40 psi

B3B1.5-13.4N 13.4 1-1/2” 40 psiB3B1.5-4.0N 4.0 1-1/2” 40 psiB3B1.5-8.3N 8.3 1-1/2” 40 psiB3B1.5-32.0N 32.0 X 1-1/2” 40 psiB3B1.5-23.5N 23.5 1-1/2” 40 psiB3B1.5-61.1N 61.1 1-1/2” 40 psi

B3B2-23.9N 23.9 2” 40 psiB3B2-56.7N 56.7 2” 40 psiB3B2-38.2N 38.2 2” 40 psiB3B2-108.5N 108.5 2” 40 psiB3B2-82.6N 82.6 2” 40 psi

B3B2.5-38.1N 38.1 2-1/2” 40 psiB3B2.5-74.1N 74.1 2-1/2” 40 psiB3B2.5-99.5N 99.5 X 2-1/2” 40 psi

Accessories. Add to list price (part no. example).

Single aux. switch (B3B3-49N+BSP-35P1U+AB-AS1)

Double aux. switch (B3B3-49N+BSP-35P1U+AB-AS2)

1,000 Ohm Potentiometer (B3B3-49N+BSP-35P1U+AB-P1K)

10,000 Ohm Potentiometer (B3B3-49N+BSP-35P1U+AB-P10K)

Options. Add to list price (part no. example). Call for delivery.

120/230 VAC power supply (B3B3-49N+BSP-35P2U)

Stainless steel stem (B3S3-49N+BSP-35P1U)

Integrated 5,000 Ohm pot. (B3B3-49N+BSP-35P1U-P5K)

Integrated 4-20 mA working range (B3B3-49N+BSP-35P1U-I20)

10-ft cable (B3B3-49N+BSP-35P1U-C3M)

Note: For Actuator Detail, See Fail-Safe Actuator Product Data, Tab #4

A B

B

A

A B

B

A

Piping Configurations

Mixing - fluid enters through two inlets (A,B) and exits through one outlet (AB)

Diverting - fluid enters through one inlet (AB) and exits through two outlets (A,B)



Three-way Threaded Equal Percentage Ball Valves with Fail-safe Actuators NEMA 4


Select valve body (B3B.5-0.33N), then actuator (BSP-35A1U). Part no.: B3B.5-0.33N+BSP-35A1U.


LINESIZE

MODELNO.

FULL1

PORTCLOSE-OFF∆P2

FLOWRATE (GPM) @ DIFFERENTIAL PRESSURE (PSI)

2-Position HVAC Apps HVAC Modulating Applications

Cv3

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 7.0 10.0

1/2”

B3B.5-0.33N

50 PSI

0.2 0.33 0.4 0.5 0.5 0.6 0.6 0.7 0.7 0.7 0.9 1.0

B3B.5-0.59N 0.4 0.59 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.3 1.6 1.9

B3B.5-1.0N 0.7 1.0 1.2 1.4 1.6 1.7 1.9 2.0 2.1 2.2 2.6 3.2

B3B.5-2.4N 1.7 2.4 2.9 3.4 3.8 4.2 4.5 4.8 5.1 5.4 6.3 7.6

B3B.5-4.3N 3.0 4.3 5.3 6.1 6.8 7.4 8.0 8.6 9.1 9.6 11.4 13.6

B3B.5-8.0N 5.7 8.0 9.8 11.3 12.6 13.9 15.0 16.0 17.0 17.9 21.2 25.3

3/4”

B3B.75-0.40N

50 PSI

0.3 0.40 0.5 0.6 0.6 0.7 0.7 0.8 0.8 0.9 1.1 1.3

B3B.75-0.66N 0.5 0.66 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.7 2.1

B3B.75-1.4N 0.9 1.3 1.6 1.8 2.1 2.3 2.4 2.6 2.8 2.9 3.4 4.1

B3B.75-2.4N 1.7 2.4 2.9 3.4 3.8 4.2 4.5 4.8 5.1 5.4 6.3 7.6

B3B.75-3.8N 2.7 3.8 4.7 5.4 6.0 6.6 7.1 7.6 8.1 8.5 10.1 12.0

B3B.75-11N • 7.8 11.0 13.5 15.6 17.4 19.1 20.6 22.0 23.3 24.6 29.1 34.8

1”

B3B1-0.40N

50 PSI

0.3 0.40 0.5 0.6 0.6 0.7 0.7 0.8 0.8 0.9 1.1 1.3

B3B1-0.65N 0.5 0.65 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.7 2.1

B3B1-1.3N 0.9 1.3 1.6 1.8 2.1 2.3 2.4 2.6 2.8 2.9 3.4 4.1

B3B1-2.3N 1.6 2.3 2.8 3.3 3.6 4.0 4.3 4.6 4.9 5.1 6.1 7.3

B3B1-3.5N 2.5 3.5 4.3 4.9 5.5 6.1 6.5 7.0 7.4 7.8 9.3 11.1

B3B1-10N 7.1 10.0 12.2 14.1 15.8 17.3 18.7 20.0 21.2 22.4 26.5 31.6

B3B1-8.6N 6.1 8.6 10.5 12.1 13.6 14.9 16.1 17.2 18.2 19.2 22.7 27.2

B3B1-22.3N 15.8 22.3 27.3 31.5 35.3 38.6 41.7 44.6 47.3 49.9 59.0 70.5

B3B1-14.9N 10.5 14.9 18.2 21.1 23.6 25.8 27.9 29.8 31.6 33.3 39.4 47.1

B3B1-4.5N 3.2 4.5 5.5 6.4 7.1 7.8 8.4 9.0 9.5 10.1 11.9 14.2

B3B1-30.8N 21.8 30.8 37.7 43.6 48.7 53.3 57.6 61.6 65.3 68.9 81.5 97.4

1-1/4”

B3B1.25-19.4N •

40 PSI

13.7 19.4 23.8 27.4 30.7 33.6 36.3 38.8 41.2 43.4 51.3 61.3

B3B1.25-12.7N 9.0 12.7 15.6 18.0 20.1 22.0 23.8 25.4 26.9 28.4 33.6 40.2

B3B1.25-4.1N 2.9 4.1 5.0 5.7 6.4 7.0 7.6 8.1 8.6 9.1 10.7 12.8

B3B1.25-8.7N 6.1 8.7 10.6 12.3 13.7 15.0 16.2 17.3 18.4 19.4 22.9 27.4

B3B1.25-34.1N • 24.1 34.1 41.8 48.2 53.9 59.1 63.8 68.2 72.3 76.2 90.2 107.8

B3B1.25-26.8N 19.0 26.8 32.8 37.9 42.4 46.4 50.1 53.6 56.9 59.9 70.9 84.7

1-1/2”

B3B1.5-13.4N

40 PSI

9.5 13.4 16.4 18.9 21.1 23.2 25.0 26.7 28.4 29.9 35.4 42.3

B3B1.5-4.0N 2.8 4.0 4.9 5.7 6.4 7.0 7.5 8.1 8.5 9.0 10.7 12.7

B3B1.5-8.3N 5.8 8.3 10.1 11.7 13.1 14.3 15.5 16.5 17.5 18.5 21.9 26.1

B3B1.5-32.0N • 22.6 32.0 39.2 45.3 50.6 55.5 59.9 64.0 67.9 71.6 84.7 101.3

B3B1.5-23.5N 16.6 23.5 28.8 33.3 37.2 40.8 44.0 47.1 49.9 52.6 62.3 74.4

B3B1.5-61.1N 43.2 61.1 74.8 86.4 96.6 105.8 114.3 122.2 129.6 136.6 161.6 193.2

2”

B3B2-23.9N

40 PSI

16.9 23.9 29.3 33.8 37.8 41.4 44.7 47.8 50.7 53.4 63.2 75.6

B3B2-56.7N 40.1 56.7 69.4 80.2 89.7 98.2 106.1 113.4 120.3 126.8 150.0 179.3

B3B2-38.2N 27.0 38.2 46.8 54.0 60.4 66.2 71.5 76.4 81.0 85.4 101.1 120.8

B3B2-108.5N 76.7 108.5 132.9 153.4 171.6 187.9 203 217 230 243 287 343

B3B2-82.6N 58.4 82.6 101.2 116.8 130.6 143.1 154.5 165.2 175.2 184.7 219 261

2-1/2”

B3B2.5-38.1N

40 PSI

26.9 38.1 46.7 53.9 60.2 66.0 71.3 76.2 80.8 85.2 100.8 120.5

B3B2.5-74.1N 52.4 74.1 90.8 104.8 117.2 128.3 138.6 148.2 157.2 165.7 196.1 234

B3B2.5-99.5N • 70.4 99.5 121.9 140.7 157.3 172.3 186.1 199.0 211 223 263 315


Flow Rates

Three-way Threaded 1 These valves are full port and do not have the linearizing insert.2 Close-off pressures measured with 35 in-lb. actuator. The close-off pressure is the maximum allowable pressure drop across the valve body when the valve is fully closed.3 C

v is defined as the quantity of water in GPM at 60°F that will flow through a given valve with a pressure drop of

1PSI. The 1.0 PSI pressure differential column in the table below is equivalent to the Cv value.



Valve Line Size

Size Through Cv 0.5 0.75 1 1.25 1.5 2 2.5 3 4

1/2”

0.33 -- 0.3 0.3

0.59 -- 0.6 0.6

1.0 -- 1.0 1.0

2.4 -- 2.3 2.3

4.3 -- 4.0 3.8 --

8.0 -- 7.9 5.7 --

3/4”

0.40 -- -- 0.4 0.4 0.4

0.66 -- 0.66 0.66 0.66

1.3 -- 1.3 1.3 1.3

2.4 -- 2.4 2.39 2.38

3.8 -- 3.8 3.74 3.7

11.0 -- 10.4 9.78 9.4

1”

0.40 -- 0.40 0.40 0.40 0.40 0.40

0.65 -- 0.65 0.65 0.65 0.65 0.65

1.3 -- 1.3 1.3 1.3 1.3 1.3

2.3 -- 2.3 2.3 2.3 2.3 2.3

3.5 -- 3.5 3.5 3.5 3.5 3.5

4.5 -- 4.5 4.5 4.5 4.4 4.4

8.6 -- 8.5 8.4 8.3 8.2 8.2

10.0 -- 9.9 9.7 9.6 9.5 9.4

14.9 -- 14.6 14.1 13.5 13.3 13.1

22.3 -- 21.2 19.9 18.4 17.7 17.3

30.8 -- 28.0 25.2 22.3 21.1 20.5

1-1/4”

4.1 -- 4.4 4.4 4.4 4.4 4.4

7.7 -- 8.3 8.2 8.2 8.2 8.1

8.7 -- 14.8 14.5 14.3 14.2 14.0

12.7 -- 35.0 31.5 29.6 28.6 27.6

19.4 -- 39.0 34.3 31.9 30.7 29.4

34.1 -- 79.1 53.3 45.5 42.0 39.0

1-1/2”

4.0 -- 4.0 4.0 4.0 4.0

8.3 -- 8.2 8.2 8.2 8.2

13.4 -- 13.3 13.2 13.2 13.1

23.5 -- 23.1 22.7 22.4 22.1

32.0 31.0 30.0 29.3 28.6

61.1 54.9 49.7 46.9 44.1

2”

23.9 -- 23.8 23.7 23.5

38.2 -- 37.8 37.3 36.62

56.7 -- 55.5 54.0 52.0

108.5 -- 100.7 92.3 83.3


Flow Rates Adjusted for Piping Geometry

Three-way Threaded



Elodrive type BE(P) actuators are designed and produced for long lasting, reliable and quiet operation of air control dampers and temperature control valves. BE(P) type actuators feature EloSafeTM electronic fail-safe technol-ogy which uses goldcap capacitors to drive the actua-tor to the fail-safe position in the event of an interruption of power. EloSafe capacitors store six times the energy required to drive the actuator to the fail-safe position under full torque load. Thermal compensation allows EloSafe actuators to deliver the full rated torque even at the lowest ambient temperature rating. A universal self-centering mounting clamp and anti-rotation strap are included with all models. All Elodrive models feature durable Elodrive brushless DC motor technology and easy manual positioning.

Highlights of the EloSafeseries of actuators: 100% self-locking even

without voltage. Full specified torque

through out the entire 90° fail-safe function Remains in a defined

fail-safe position with 100% self-locking Fail-safe function also

possible when control signal (2-10 V) is missing

Technical Data Electric Actuator Type BE(P)Characteristic 24 V 120/230 VNominal voltage AC 24 V +/-20%, 50/60 Hz, DC 24 to 36 V +/-10% AC 90-264 V, 50/60 Hz

Electrical connection 3-ft plenum rated cable, 1/2-inch conduit fitting

Starting current .5 A for approx. 40 SecSynchronization +/- 5%Rotation direction Selectable via switch L/R (CCW/CW) or by L/R mountingAngle of rotation Max. 95°Manual adjustment Standard allen key positioning without disengaging gearsShaft mounting Centered, Ø 0.3in [8mm]-0.8in [20mm]; ◊ 0.2in [6mm]-0.6in [14mm]

Running time 90 sec (+/- 5%), during normal operation; independent of load; Fail-safe operation approx. 30 sec

Position indicator MechanicalNoise emission level < 35 dB (A), Fail-safe operation < 60 dB (A)Ambient temperature -22 to +122°F [-30 to +50°C]Storage temperature -40 to +176°F [-40 to +80°C]Humidity 5 to 95% RH non-condensing (excludes NEMA 4 models)Quality Standard ISO - 9001

Agency listings (Listing for all 120/230 V power supply models is pending)

Weight 2.1 lb [950 g]Maintenance Maintenance free

ModelProtection

DegreeMin. Torque

(in-lb)

Power Supply 24VDC,

120/230VAC

Power Consumption

Max.

Power Consumption

Damper Area approx. sq-ft

BE SeriesOn/Off Control, 90 Second Running Time Drive, 60 Second Running Time Fail-safe

BE-88A1U NEMA 2 88 24 20.0VA 9.0VA 22BE-88A2U NEMA 2 88 120/230 20.0VA 12.0VA 22BEP-88A1U NEMA 4 88 24 20.0VA 9.0VA 22BEP-88A2U NEMA 4 88 120/230 20.0VA 12.0VA 22BE-132A1U NEMA 2 132 24 20.0VA 9.0VA 33BE-132A2U NEMA 2 132 120/230 20.0VA 12.0VA 33BEP-132A1U NEMA 4 132 24 20.0VA 9.0VA 33BEP-132A2U NEMA 4 132 120/230 20.0VA 12.0VA 33

Directional Control, 90 Second Running Time Drive, 30 Second Running Time Fail-safe

BE-88D1U NEMA 2 88 24 20.0VA 9.0VA 22BE-88D2U NEMA 2 88 120/230 20.0VA 12.0VA 22BEP-88D1U NEMA 4 88 24 20.0VA 9.0VA 22BEP-88D2U NEMA 4 88 120/230 20.0VA 12.0VA 22BE-132D1U NEMA 2 132 24 20.0VA 9.0VA 33BE-132D2U NEMA 2 132 120/230 20.0VA 12.0VA 33BEP-132D1U NEMA 4 132 24 20.0VA 9.0VA 33BEP-132D2U NEMA 4 132 120/230 20.0VA 12.0VA 33

Floating Point Control, 90 Second Running Time Drive, 30 Second Running Time Fail-safe

BE-88F1U NEMA 2 88 24 20.0VA 9.0VA 22BE-88F2U NEMA 2 88 120/230 20.0VA 12.0VA 22BEP-88F1U NEMA 4 88 24 20.0VA 9.0VA 22BEP-88F2U NEMA 4 88 120/230 20.0VA 12.0VA 22BE-132F1U NEMA 2 132 24 20.0VA 9.0VA 33BE-132F2U NEMA 2 132 120/230 20.0VA 12.0VA 33BEP-132F1U NEMA 4 132 24 20.0VA 9.0VA 33BEP-132F2U NEMA 4 132 120/230 20.0VA 12.0VA 33

Proportional Control 0/2-10VDC, 90 Second Running Time Drive, 30 Second Running Time Fail-safe

BE-88P1U NEMA 2 88 24 20.0VA 9.0VA 22BE-88P2U NEMA 2 88 120/230 20.0VA 12.0VA 22BEP-88P1U NEMA 4 88 24 20.0VA 9.0VA 22BEP-88P2U NEMA 4 88 120/230 20.0VA 12.0VA 22BE-132P1U NEMA 2 132 24 20.0VA 9.0VA 33BE-132P2U NEMA 2 132 120/230 20.0VA 12.0VA 33BEP-132P1U NEMA 4 132 24 20.0VA 9.0VA 33BEP-132P2U NEMA 4 132 120/230 20.0VA 12.0VA 33


Fail-Safe Actuator Product Data


Electric Actuator Type BE(P)Electronic Fail-Safe, 88/132 in-lb Minimum Torque, BE NEMA 2 / BEP NEMA 4

Note: See binder tab no. 5 for actuator accessories/options product data.

Technical Data Electric Actuator Type BE(P)

On/Off

Wiring schematicsOn/Off

Directional

Wiring schematicsDirectional

Floating Point

Wiring schematicsFloating Point

Proportional 0/2-10 V

Input signal 0-10 V or 2-10 V selectable via switch

Input impedance >100 kΩ

Output signal DC 0/2-10 V for 0-100%

Wiring schematicsProportional 0/2-10 V

6.8 [173.6]

0.9[22.8]

0.3 [6.5]

2.1

[53.

6]0.3

[6.5]

0.3 [6.

5]

2.6

[66.

6]

0.3 [6.5]

7.8 [199]7.6 [194]

0.7

[19]

2.4

[60]

3.1

[7.9

]

All Dimensions in inches and metric [mm]

Fail-Safe Actuator Product Data

black

red

white

black

black

red

light blue

white

black

light blue

black

red

light blue

green

white

black

light blue

green

black

red

light blue

green

white

black

light blue

yellow

gray


Standard delivery includes:

Anti-rotation strap

Centric clamp adaptor

Allen key

Position indicator

Mechanical rotation limit stops

Operation manual

Refrigerant Compatibility

Compatibilidade do Refrigerante

Compatibilité du réfrigérant

R-11R-12R-22R-113R-114R-115

R-123R-124R-125R-134aR-401A

R-407BR-407CR-410AR-500R-502R-507

R-401BR-402AR-402BR-404AR-407A

Verify Coil

Verifique la Bobina

Verifique a bobina

1 2

Compatibilidad con Refrigerantes

ModelCoil

AM AH DM MM ASC2

100RB

200RB

240RA

500RB

540RA

üüü

üüü

üüüüü

üüüüü

üüüüüü ü

Vérifier la bobine

Valve Orientation

Orientación de Válvulas

Orientação da Válvula

Orientation de la valve

Do Not Bend Enclosing Tube

No doble el casquillo del Embolo de la Aguja

Não danifique o tubo de apoio da bobina

Flow Follows Arrow

Barra Indica Posição do Fluido

L’écoulement doit suivre la flèche

3 4 5

El Flujo sigue la Flecha

Ne pas plier le tube

6

Coil Installation

Instalación de la Bobina

Instalação da bobina

Solder Techniques

Técnicas para Soldar

Técnicas de Soldagem

Technique de soudure

7

l’installation de la bobine

Solenoid Valves200RD Model

T < 250°F (121°C)

Type T

AM Coil Electrical Data

VAC/HzMaximum Amps VA

HoldingInrush Holding

24/50 2.0 0.96 23

24/60 1.6 0.74 18

120/50 0.45 0.21 25

120/60 0.36 0.16 19

208/50 0.19 0.08 17

208/60 0.15 0.06 12

220/50 0.24 0.10 24

240/60 0.19 0.08 19

480/50 0.11 0.05 24

480/60 0.09 0.04 19

9

Transformer Selection

Selección del Transformador

Selecione transformador capacidade suficiente

Sélection du transformateur

Emerson Climate Technologies and the Emerson Climate Technologies logo are trademarks and service marks of Emerson Electric Co. © 2004 Emerson Electric Co. PA-00326 Apr 2009

Manual OverrideDisassembly - must use new gasket when reassembling - retorque per table above

Vástago de Operación Manual

Desmontagem - quando for remontar é necessáriousar uma nova gaxeta - reaperte utilizando a tabela acimaAcionamento manual

Desmontaje - cuando este remontando usar una nueva empaquetadora - reajuste utilizando la tabla encima

Désassemblé - doit utiliser un nouveau segment lors du réassemblage - rétorqué selon la table si dessusOuverture manuel de la tige

t

t

50 in.-lb.(5.6 N•m)t

t

350 in.-lb.(39.5 N•m)

200RD 7-12

225 in.-lb.(25.4 N•m)

200RD 2-6

10 11

2004FC-118 (Q4/09) 8

Solenoid Valves & Coils

Features• One coil fi ts all valve sizes• Extended ends for easy installation (standard)• Long-life molded coils• PTFE O-ring for superior external sealing

Options• Available in 5 orifi ce sizes• Manual stem or mounting stud• Bi-Flow operation-conversion either factory assembled or with kit except 200RD 7,9 & 12

Specifications• Maximum fl uid temperature: 250°F • Maximum working pressure: 680 psig• Minimum operating pressure drop: 2 psi• MOPD: 550 psig• UL/CUL fi le number: MP604

NOTE: Mounting enclosing tube more than 90o off vertical up position is not recommended.

The 200RD is a pilot-operated, 2-way, normally closed, R-410A valve. 200RD valves are used for liquid, discharge, or suc-tion gas refrigerant service.

Nomenclature example: 200RD 4T3M VLC

200R D 4 T 3 M VLCValve Series Design

SeriesPort Size (in 1/16”)

Connection TypeT = Copper Extended Ends

Connection Size(In 1/8”)

M = manual stemT = mounting stud

(optional)

Coil*

*NOTE: Valves are shipped without the solenoid coils (VLC = Valve Less Coil). See available coil assemblies.

Ordering Information and Nominal * Liquid Capacity - Tons (kW)PCN

Description Connection Size R-410AStandardValve

MountingStud1

ManualStem2

066158 066179 – 200RD 2 T 2 1/4 ODF3.2 (11.3)

066159 066180 – 200RD 2 T 3 3/8 ODF

066160 – – 200RD 3 T 2 1/4 ODF

4.5 (15.8)066161 066182 066203 200RD 3 T 3 3/8 ODF

066162 066183 066204 200RD 3 T 4 1/2 ODF

066163 066184 066205 200RD 4 T 3 3/8 ODF

7.3 (25.7)066164 066185 066206 200RD 4 T 4 1/2 ODF

066165 066186 006207 200RD 4 T 5 5/8 ODF

066166 066187 066208 200RD 5 T 3 3/8 ODF

7.7 (27.1)066167 066188 066209 200RD 5 T 4 1/2 ODF

066168 066189 066210 200RD 5 T 5 5/8 ODF

066169 066190 066211 200RD 6 T 4 1/2 ODF8.8 (30.9)

066170 066191 066212 200RD 6 T 5 5/8 ODF1 Add “T” to the end of description for Mounting Stud2 Add “M” to the end of the description for Manual Stem

Capacities based on ARI standard. *See Extended Capacity Tables for ratings at a wide range of conditions.

200RDR-410A

2004FC-118 (Q4/09) 9

Solenoid Valves & Coils200RD

With Extended Ends

Valve Port Size Conn. Size & Style A B C200RD 2T2 1/8 1/4 ODF

2.42 4.62

0.25200RD 2T3 3/8 ODF 0.31200RD 3T2

3/161/4 ODF 0.25

200RD 3T3 3/8 ODF 0.31200RD 3T4 1/2 ODF 0.38200RD 4T4 1/4 2.50 5.00200RD 4T5 5/8 ODF 3.25 6.50 0.50200RD 5T3

5/163/8 ODF 2.31 4.62 0.31

200RD 5T4 1/2 ODF 2.50 5.00 0.38200RD 5T5 5/8 ODF 3.25 6.50 0.50200RD 6T3

3/83/8 ODF 2.31 4.62 0.31

200RD 6T4 1/2 ODF 2.50 5.00 0.38200RD 6T5 5/8 ODF 3.25 6.50 0.50

1.77

0.85

3.41

A

B

C

0.59

2 IN. REQUIREDFOR COIL REMOVAL

With Extended Ends

Exploded View& Parts Kit Data

Valve Repair Kit“K” indicates part is supplied in

valve repair kit KS30386. (PCN 066223)

Gasket KitGasket Kit KG10025 (PCN 049190)

(contains 12 pieces - each of PTFE and neoprene O-rings)

Coil AssemblySee coil assemblies for availability.

Bi-Flow Conversion KitKS30387 (PCN 066224)

2008

TechnicalHelp Guide

Thermal Expansion ValvesSolenoid Valves

System ProtectorsRegulatorsOil Controls

Temperature Pressure ControlsBasic Rules of Good Practice

Troubleshooting Guide

2008

Introduction

This Technical Guide from Emerson Climate Technologies provides a de-tailed explanation on the operation of common refrigeration system components such as thermal expansion valves, solenoid valves, system protectors, regula-tors, oil controls and temperature pressure controls. Also included in this guide is a listing of the basic rules of good practice and a detailed troubleshooting guide. This guide is designed to fill a need which exists for a concise, elementary text to aid servicemen, salesmen, students and others interested in refrigeration and air conditioning. It is intended to cover only the fundamentals of refrigeration and air conditioning theory and practice. Detailed information for specific products is available from manufacturers of complete units and accessories. Used to supple-ment such literature, and to improve general knowledge of refrigeration and air conditioning, this guide should prove to be very helpful.

Emerson Climate Technologies, a business of Emerson, is the world’s leading provider of heating, ventilation, air conditioning and refrigeration solutions for residential, industrial and commercial applications. The group combines best-in-class technology with proven engineering, design, distribution, educational and monitoring services to provide customized, integrated climate-control solutions for customers worldwide. Emerson Climate Technologies’ innovative solutions, which include industry-leading brands such as Copeland Scroll and White-Rodgers, improve human comfort, safeguard food and protect the environment.

Emerson Climate Technologies - Flow Controls Division is a leading manufacturer of valves, controls and system protectors commonly applied in air conditioning and refrigeration systems worldwide. The company continues to pioneer the control of refrigerant flow through innovative, high performance components, such as thermal expansion valves and filter driers.

2008

Table of ContentsThermal Expansion Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Internal Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Factory Setting of TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 External Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TXV Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Application Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Balanced Port TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 M .O .P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Other TXV Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Emerson TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 What are Solenoid Valves? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Principles of Solenoid Operation . . . . . . . . . . . . . . . . . . . . . . . . 15 Types of Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Emerson Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18System Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Filter-driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 HFC Refrigerants and POE Lubricants . . . . . . . . . . . . . . . . . . . . 22 Clean-up Procedure for Compressor Motor Burnout . . . . . . . . 25 Emerson System Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Suction Line Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Applications of EPRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Crankcase Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Headmaster Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Liquid Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Oil Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Temperature Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Basic Rules of Good Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2008

Thermal Expansion Valves


P1 = 45.4 PSIG

P2 = 35 PSIGP3 = 10.4 PSIG

35 PSIG = 40°F

35 PSIG = 40°F

35 PSIG = 50°F

B

C

TXV with internalequalizer on evaporator with

no pressure drop. Fig. 1

A

is charged with the same refrigerant as that in the sys-tem. The power assembly pressure (P1), which corre-sponds to the saturation pressure of the refrigerant gas temperature leaving the evaporator, moves the TXV pin in the opening direction. Opposed to this opening force on the underneath side of the diaphragm and acting in the closing direc-tion are two forces: the force exerted by the evaporator pressure (P2) and that exerted by the superheat spring (P3). In the first condition, the TXV will assume a stable control position when these three forces are in balance (P1 = P2 + P3). See figure 1A.


The most commonly used device for controlling the flow of liquid refrigerant into the evaporator is the ther-mostatic expansion valve (TXV). Also known as thermal expansion valves, TXVs are precision devices designed to regulate refrigerant liquid flow into the evaporator in exact proportion to evaporation of refrigerant liquid in the evaporator. Refrigerant gas leaving the evaporator can be regu-lated since the TXV responds to the temperature of the refrigerant gas leaving the evaporator and the pres-sure in the evaporator. This controlled flow prevents the return of refrigerant liquid to the compressor. The TXV controls the flow of refrigerant by maintaining a pre-de-termined superheat. An orifice in the TXV meters the flow into the evapo-rator. Flow is modulated as required by a needle type plunger and seat, which varies the orifice opening. The needle is controlled by a diaphragm subject to three forces:1. The power element and remote bulb pressure (P1)2. The evaporator pressure (P2)3. The superheat spring equivalent pressure (P3)These forces are shown in Figure 1.

Internal Equalizer

Three conditions are present in the operation of a TXV: . The balanced forces . An increase in superheat 3. A decrease in superheat The remote bulb and power element make up a closed system (power assembly), and in the following discussion, it’s assumed that the power assembly

If the temperature of the refrigerant gas at the evaporator outlet (remote bulb location) rises above the saturation temperature corresponding to the evaporator pressure as it becomes superheated (P1 greater than P2 + P3), the TXV pin moves in an opening direction. When the temperature of the refrigerant gas leaving the evaporator decreases, the pressure in the remote bulb and power assembly also decreases and the com-bined evaporator and spring pressure cause the TXV pin to move in a closing direction (P1 less than P2 + P3). For example, when the evaporator is operating with R-134a at a temperature of 40°F or a pressure of 35 psig and the refrigerant gas leaving the evaporator at the remote bulb location is 45°F a condition of 10°F superheat exists. Since the remote bulb and power as-sembly are charged with the same refrigerant as that used in the system R-134a, its pressure (P1) will follow its saturation pressure-temperature characteristics. With the liquid in the remote bulb at 45°F, the pressure inside the remote bulb and power assembly will be 40 psig acting in an opening direction. Beneath the diaphragm and acting in a closing direction are the evaporator pres-sure (P2) of 35 psig and the spring pressure (P3) for a 10°F superheat setting of 5 psig (35 psi + 5 psi = 40 psi) making a total of 40 psig. The TXV is balanced, 40 psig above and 40 psig below the diaphragm.

The following sections describe the operation and ap-plication of single-outlet TXVs in two general categories: internally equalized and externally equalized.

3


Changes in load cause the TXV pin to move:• Increasing the superheat will cause the TXV to open• Decreasing the superheat will cause the TXV to close

Factory Settings of TXVs

The factory superheat setting of TXVs is made with the TXV pin just starting to move away from the seat. The superheat necessary to get the pin ready to move is called static superheat. TXVs are designed so that an increase in superheat of refrigerant gas leaving the evaporator is needed for the TXV pin to open to its rated position. This added superheat is known as gradient. For ex-ample, if the factory static is 6°F superheat, the operat-ing superheat at the rated stroke or pin position (full load rating of TXV) will be 10°F to 14°F superheat (See fig. 2).

Manufacturers usually furnish the adjustable type TXV with a factory static superheat setting of 6°F to 10°F unless otherwise specified. When using non-adjustable TXVs, it’s important that they are ordered with the correct factory superheat setting. For manufacturer’s production lines it is recom-mended that an adjustable TXV be used in a pilot model lab test to determine the correct factory superheat set-ting before ordering the non-adjustable type TXV. If the operating superheat is raised unnecessarily high, the evaporator capacity decreases, since more of the evaporator surface is required to produce the super-heat needed to operate the TXV. A minimum change of superheat to open the TXV is important because it provides savings in first cost of the evaporator and cost of operation. The TXV described so far is internally equalized, where the evaporator pressure at the TXV outlet is admitted internally and allowed to exert its force beneath the diaphragm. In the next section the externally equal-ized TXV will be discussed.

External Equalizer

A TXV with an external equalizer is required when the pressure drop through the evaporator is substantial: • 3°F for residential air conditioning • 2°F for commercial air conditioning • 1°F for refrigeration low temperature range

This is because the pressure drop will hold the TXV in a fairly “restricted” position and reduce system capac-ity. The evaporator should be designed or selected for the operating conditions and the TXV selected and ap-plied accordingly.

For example, an evaporator is fed by a TXV with an internal equalizer, where a sizable pressure drop of 10 psi is present (See fig. 3). The pressure at point “C” is 25 psig or 10 psi lower than at the TXV outlet, point “A”, however, the pressure of 35 psig at point “A” is the pressure acting on the lower side of the diaphragm in a closing direction. With the TXV spring set at a compres-sion equivalent to 10°F superheat or a pressure of 10.4 psig, the required pressure above the diaphragm to equalize the forces is (35 + 10.4) or 45.4 psig. This pres-sure corresponds to a saturation temperature of 50°F. The refrigerant temperature at point “C” must be 50°F if the TXV is to be in equilibrium. Since the pressure at this point is only 25 psig and the corresponding satura-tion temperature is 28°F, a superheat of (50°F - 29°F) or 21°F is required to open the TXV.

This increase in superheat, from 10°F to 21°F means that more of the evaporator surface needs to be used to produce this higher superheated refrigerant gas. The evaporator surface available for absorption of heat is re-duced and the evaporator is starved before the required superheat is reached.

P1 = 45.4 PSIG

P2 = 35 PSIGP3 = 10.4 PSIG

35 PSIG = 40°F

25 PSIG = 29°F

25 PSIG = 50°F

B

C


10 PSI drop. Fig. 3

A

Since the pressure drop across the evaporator in-creases with load, the restricting effect becomes worse when the demand on the TXV capacity is greatest.

4


This change from 10°F to 11°F in the operating superheat is caused by the change in the pressure- temperature characteristic of R-134a at the lower suction pressure of 25 psig.

Location of External Equalizer

The external equalizer line must be installed beyond the point of greatest pressure drop. Since it may be dif-ficult to determinate this point, it is best to connect the equalizer line to the suction line at the evaporator outlet on the compressor side of the remote bulb location. (See fig. 4 & 5). When the external equalizer is con-nected to a horizontal line, always make the connection at the top of the line to avoid oil logging in the equalizer line.

On a multi-evaporator system including two or more evaporators each fed by a separate TXV, the external equalizer lines must be installed so that they will be free from the effect of pressure changes in the evaporators fed by other TXVs. At no time should the equalizer lines be joined in a common line to the main suction line.

If individual suction lines from the separate evapora-tor outlets to the common suction line are short, then install the external equalizer lines into the separate evaporator suction headers, or as described in the pre-ceding paragraph.

When the pressure drop through the evaporator is not substantial, install the external equalizer connection at one of the return bends midway through the evapora-tor. This equalizer location will provide smoother TXV control when used in conjunction with an Evaporator Pressure Regulator. Anytime a control valve is installed in the suction line, the external equalizer line for the TXV must be connected on the evaporator side of the control valve or regulator.

Never cap or plug the external equalizer connection on a TXV, as it will not operate. If the TXV is furnished with an external equalizer feature, the external equalizer line must be connected.

P1 = 35 PSIG

P2 = 25 PSIGP3 = 10 PSIG

35 PSIG = 40°F

25 PSIG = 29°F

25 PSIG & 40°F

B

C

TXV with externalequalizer on evaporator with

10 PSI pressure drop. Fig. 4

A

To compensate for an excessive pressure drop through an evaporator, the TXV must be externally equalized. The equalizer line should be connected to the suction line at the evaporator outlet, past the remote bulb location so that the true evaporator outlet pressure is exerted beneath the TXV diaphragm. The operating pressure on the TXV diaphragm is now free from any effect of the pressure drop through the evaporator, and the TXV will respond to the superheat of the refrigerant gas leaving the evaporator.

When the same conditions of pressure drop exist in a system with an externally equalized TXV (see fig. 4), the same pressure drop still exists through the evaporator, however, the pressure under the diaphragm is now the same as the pressure at the end of the evaporator, point “C”, or 25 psig.

The required pressure above the diaphragm for equi-librium is (25 + 10) or 35 psig. This pressure, 35 psig, corresponds to a saturation temperature of 40°F and the superheat required is now (40°F minus 29°F) 11°F. The external equalizer has lowered superheat from 22°F to 11°F. The capacity of a system having an evapora-tor with a sizable pressure drop will be increased by a TXV with the external equalizer when compared to an internally equalized TXV.

When the pressure drop through an evaporator is substantial, or when a refrigerant distributor is used at the evaporator inlet, the TXV must have the external equalizer feature for best performance.

An externally equalized TXV is required when a liquid distributor is used. Although a multi-circuit evaporator may not have an excessive pressure drop, the liquid distributor will introduce a pressure drop, because the distributor is installed between the TXV outlet and the evaporator inlet (See fig. 5).

5


P1 = 45.5 PSIG

P2 = 35 PSIGP3 = 10.4 PSIG

35 PSIG = 40°F

35 PSIG = 40°F

35 PSIG = 50°F

B

C


no pressure drop. Fig. 6

A

Superheat

A vapor is said to be superheated whenever its temperature is higher than the saturation temperature corresponding to its pressure. The superheat equals the temperature increase above the saturation temperature at that pressure. For example, a refrigeration evapora-tor is operating with R-134a at 35 psig suction pressure (See fig. 6). The R-134a saturation temperature at 35 psig is 40°F. As long as any liquid exists at this pressure, the refrigerant temperature will remain 40°F as it evapo-rates or boils off in the evaporator.

suring superheat, install a calibrated pressure gauge in a gauge connection at the evaporator outlet. In the ab-sence of a gauge connection, a tee installed in the TXV external equalizer line can be used just as effectively.

A refrigeration type pocket thermometer with appro-priate bulb clamp or an electric thermometer with ther-mocouples may be used to measure gas temperature.

The temperature element from the thermometer should be taped to the suction line at the point of remote bulb location and must be insulated. Thermometers will give an average reading of suction line and ambient if not insulated. Assuming an accurate gauge and ther-mometer, this method will provide accurate superheat readings.

Approximate Methods of Reading Superheat

When a gauge connection is not available and the TXV is internally equalized there are two ways of esti-mating superheat. Neither of these methods will yield an exact superheat reading.

The first is the two-temperature method, which uses the difference in temperature between the evaporator inlet and outlet as the superheat. The error is caused by the pressure drop in the evaporator. When the pressure drop between the evaporator inlet and outlet is 1 psi or less, the two-temperature method will yield fairly accu-rate results. But evaporator pressure drop is usually not known and will vary with load. For this reason, the two-temperature method cannot be relied on for absolute superheat readings. The error in this method is negative and always shows a lower superheat.

The second method involves taking the temperature at the evaporator outlet and using the compressor suc-tion pressure as the evaporator saturation pressure. The error is caused by the pressure drop in the suction line between the evaporator outlet and the compressor suc-tion gauge. On packaged equipment and close-coupled installations, the pressure drop and resulting error are usually small. But on large built-up systems or systems with long runs of suction lines, considerable error can result. Since estimates of suction line pressure drop are usually not accurate enough to give a true picture of the superheat, this method cannot be relied on for absolute values. The error in this method is positive and always shows a higher superheat.

The only method for checking superheat that will yield an absolute value involves a pressure and tem-perature reading at the evaporator outlet .

By realizing the limitations of these approximate methods and the direction of the error, it is often pos-

As the refrigerant moves along in the coil, the liquid boils off into a vapor. The liquid is completely evapo-rated at point B because it has absorbed enough heat to change the refrigerant liquid to a vapor. The refrigerant gas continues along the coil and remains at the same pressure (35 psig); however, its temperature increases due to continued absorption of heat. When the refriger-ant gas reaches the end of the evaporator (point “C”) its temperature is 50°F. This refrigerant gas is now super-heated and the superheat is 10°F. (50°F minus 40°F).

The amount of superheat depends on how much re-frigerant is being fed into the evaporator by the TXV and the heat load to which the evaporator is exposed.

Superheat Adjustment

The function of a TXV is to control the superheat of the suction gas leaving the evaporator. If superheat is within reasonable limits, the TXV is operating in a satis-factory way. If superheat cannot be checked directly, it is important to know the size and direction of whatever error is present.

The pressure and temperature of the refrigerant suc-tion gas passing the TXV remote bulb are required for an accurate determination of superheat. When mea-


sible to determine that the cause of the trouble call is because of improper methods of instrumentation rather than any malfunction of the TXV.

When troubleshooting in mountain areas (such as Denver, Colorado or Salt Lake City, Utah) use a Pressure-Temperature chart that has correct readings such as Emerson Climate Technologies’ 5,000 ft. pocket chart. Gauge pressures will read lower than they would at sea level.

TXV Selection Proper TXV size is determined by the BTU/HR or

tons load requirement, the pressure drop across the TXV, and the evaporator temperature. Do not assume that the pressure drop across the TXV is equal to the difference between discharge and suction pressures at the compressor. This assumption could lead to incorrect sizing of the TXV.

The pressure at the TXV outlet will be higher than the suction pressure at the compressor because of the fric-tional losses through the distribution header, evaporator tubes, suction lines, fittings, and hand valves. On rack systems, the EPR valve also adds substantial pressure drop.

The pressure at the TXV inlet will be lower than the discharge pressure at the compressor because of fric-tional losses created by the length of liquid line, valves and fittings, and vertical lift. The only exception is if the TXV is installed considerably below the receiver and static head built up is more than enough to offset fric-tional loses. The liquid line should be properly sized for its actual length plus equivalent length due to fitting and hand valves. Vertical lift in the liquid line adds pressure drop and thus static head must be included.

The pressure drop across the TXV will be the differ-ence between the discharge and suction pressures at the compressor less the pressure drops in the liquid line, through the distributor, evaporator, and suction line.

ASHRAE tables should be consulted for determining pressure drops in liquid and suction line.

Here is the procedure for properly selecting a TXV:

1. Determine pressure drop across TXV: using the maximum and minimum condensing pressures, subtract the evaporating pressure from each to get the total high-to-low side pressure drop. From these values subtract the other possible pressure losses– piping and heat exchanger losses; pressure drop thru accessories; verti-cal lift pressure drop; and the pressure drop across the refrigerant distributor.

2. Consider the maximum and minimum liquid tempera-tures of the refrigerant entering the TXV and select the correction factors for those temperatures from the table below the capacity ratings. Determine the corrected ca-pacity requirement by dividing the maximum evaporator load in tons by the liquid correction factors.

3. Select the TXV size from the proper capacity table for the evaporator temperature, pressure drop available, and corrected capacity requirement.

4. Select the proper thermostatic charge based on the evaporator temperature, refrigerant, and whether a Maximum Operating Pressure (see MOP section) type charge is needed.

5. Determine connections and whether an externally equalized model is required. Always use an externally equalized TXV when a distributor is used.

A solid column of liquid refrigerant is required for proper TXV operation. Calculate the pressure drop in the liquid line to determine if there will be enough subcooling to prevent flash gas. If the subcooling of the liquid refrigerant from the condenser is not adequate, then a heat exchanger, liquid subcooler, or some other means must be used to get enough subcooling to en-sure solid liquid entering the TXV at all times.

Emerson Climate Technologies has prepared extended TXV capacity tables. These tables can be found in the Emerson catalog. Always select a TXV based on operating conditions rather than nominal TXV capacities.


Application Tips

For best evaporator performance, the TXV should be installed as close to the evaporator as possible and in an easily-accessible location for adjustment and servic-ing. On pressure drop and centrifugal type distributors, apply the TXV as close to the distributor as possible. (See fig.7)

sion and faulty remote bulb contact with the line.On lines smaller than 7/8” OD the remote bulb may

be installed on top of the line. With 7/8” OD and over, the remote bulb should be installed at the position of about 4 or 8 o’clock. (See fig. 8)

It is good practice to insulate the bulb with a material which will not absorb moisture.

Remote Bulb Well

A remote bulb well will improve the sensitivity of the remote bulb. This occurs with short coupled installations and installations with large suction lines (2-1/8” OD or larger). Remote bulb wells should be used when low superheat is desired or where converted heat from warm rooms can influence the remote bulb. (See fig. 9).

Remote Bulb Location

Since evaporator performance depends on good TXV control, and TXVs respond to the temperature change of the refrigerant gas leaving the evaporator, care must be given to types of remote bulbs and their locations. The external remote bulb meets the requirements of most installations. The bulb should be clamped to the suction line near the evaporator outlet on a horizontal run. If more than one TXV is used on adjacent evaporators or evaporator sections, make sure that remote bulb of each TXV is applied to the suction line of the evaporator fed by that TXV.

Clean the suction line thoroughly before clamping the remote bulb in place. When a steel suction line is used, paint the line with aluminum paint to reduce future corro-

Never install a remote bulb in a location where the suction line is trapped (See fig. 10). If the liquid refriger-ant collects at the point of remote bulb location the TXV operation will be erratic.


Large fluctuations in superheat in the suction gas are usually the result of trapped liquid at the remote bulb location. Even on properly designed suction lines, it is sometimes necessary to move the remote bulb a few inches from the original location to improve TXV perfor-mance.

On multi-circuit evaporators fed by one TXV, install the remote bulb at a point where the suction gas has had an opportunity to mix in the suction header. Tighten clamps so that the remote bulb makes good contact with the suction line. NEVER APPLY HEAT NEAR THE REMOTE BULB LOCATION WITHOUT FIRST RE-MOVING THE REMOTE BULB.

Hunting

“Hunting” of TXVs is defined as the alternate over-feeding and starving of the refrigerant flow to the evaporator. Hunting is characterized by extreme cyclic changes in the superheat of the refrigerant gas leaving the evaporator and the evaporator or suction pressure.

Hunting is a function of the evaporator design, length and diameter of tubing in each circuit, load per circuit, refrigerant velocity in each circuit, temperature differ-ence (TD) under which the evaporator is operated, ar-rangements of suction piping and application of the TXV remote bulb. “Hunting” can be reduced or eliminated by the correct rearrangement of the suction piping, reloca-tion of the bulb and use of the recommended remote bulb and power assembly charge for the TXV.

Operation at Reduced Capacity

The conventional TXV is a self-contained direct oper-ated regulator which is inherently susceptible to hunting because of its design and the design of the system to which it is applied.

The ideal flow rate would require a TXV with perfect dynamic balance, capable of instantaneous response to any change in evaporation (anticipation) and with a means of preventing the TXV from over shooting the control point because of inertia (compensation). With these features a TXV would be in phase with the system demand at all times and hunting would not occur.

A conventional TXV does not have built in anticipating or compensating factors. A time lag will exist between demand and response, along with the tendency to over shoot the control point. The conventional TXV may get out of phase with the system and hunt. An example of overshooting occurs when the load increases, causing the superheat of the suction gas to increase. The time interval between the instant the remote bulb senses the increase and causes the TXV pin to move into opening

direction allows the superheat of the gas to increase still further.

In response to the rising superheat during the time lags, the TXV has moved further in the opening direc-tion, overshooting the control point and allowing more refrigerant to flow to the evaporator than can be boiled off by load.

When the TXV finally responds to the over-feeding of the evaporator coil, it closes and will tend to again over-shoot the control point and remain overly throttled until most of the liquid refrigerant has left the evaporator.

The ensuing time delay before the TXV moves in the opening direction allows superheat of the suction gas to again rise beyond the control point. This cycle, being self-propagating, continues to repeat.

Experience has shown that a TXV is more likely to hunt at low load conditions when the TXV pin is close to the valve seat. This is because of an unbalance be-tween the forces which operate the TXV.

Besides the three main forces that operate the TXV, the pressure difference across the TXV port also acts against the port area and depending on TXV construc-tion, tends to force the TXV either open or closed.

When operating with the pin close to seat, the follow-ing will occur:

With the TXV closed, there is liquid pressure on the inlet side of the pin and evaporator pressure on the outlet.

When the TXV starts to open allowing flow to take place, the velocity through the TXV throat will cause a point of lower pressure at the throat, raising the pressure difference across the pin and seat.

This sudden rise in pressure differential while acting on the port area will tend to force the TXV pin back into the seat. When the TXV again opens, the same type of action occurs and the pin bounces off the seat with a rapid frequency. This phenomenon is more frequently encountered with the larger conventional ported TXVs as compared to balance ported TXVs as the force caused by the pressure differential is magnified by the larger port area.

Most TXVs, when properly selected and applied, will overcome these factors and operate with virtual no hunt-ing over a fairly wide load range.

Conventional ported TXVs will operate satisfactory to somewhat below 50% of nominal capacity depending on evaporator design, refrigerant piping, size and length of evaporator, and rapid changes in loading.

Nothing will cause a TXV to hunt quicker than un-equal feeding of the parallel circuits by a distributor or unequal air loading across the evaporator circuits.

9


Balanced Port TXV Operation

In conventional TXVs, as the pressure drop across the TXV port changes due to changes in head pressure or suction pressure, the operating superheat of the TXV will vary.

Depending on the operating conditions under which the superheat was originally set, this “unbalance” can sometimes result in compressor flooding or evaporator starvation. A unique design concept called “Balanced Port” cancels the effect of this pressure unbalance, per-mitting the TXV to operate at a fairly constant superheat over a wide range of operating conditions.

There are 2 fundamental Balanced Port designs:Double Ported Design (Figure 11a) – In this design, there are 2 paths for the refrigerant to flow. One path creates a force that tends to push the pin in the “open” direction; whereas the other path creates a force push-ing the pin in the “closed” position. These paths are de-signed in such a way that the forces generated in each path are equal to one another, resulting in a “balanced” design.Single Ported Design (Figure 11b) – In this design, the valve pin has a shoulder added that is on the inlet side of the valve. The high pressure times the area of the shoulder results in an upward (closing) force. The pres-sure differential across the pin results in a “downward” force. By designing the shoulder carefully, the downward force is negated or “balanced”.

Any refrigeration system which experiences changes in operating pressures because of varying ambient, gas defrost, heat reclaim, or swings in evaporator load will benefit from using a balanced port TXV.

M .O .P .

Maximum Operating Pressure (sometimes referred to as Motor Overload Protection) is the ability of a TXV to close down, starve, or shut off if the suction pressure should approach a dangerously high predetermined limit condition. These conditions could overheat a suction cooled compressor or load the crankcase with too dense a vapor pressure. With the TXV in a closed condition the compressor has a chance to gain pull the suction back down to satisfactory operating conditions. Once below the MOP, the TXV will re-open and feed normally or until there is an overload again.

Power Element Charges

There are several basic types of charges in use today. Most common are the: liquid charge; gas charge; liquid cross-charge; gas cross-charge; and the adsorp-tion charge.

Liquid Charges

The power element contains the same refrigerant as the system in which the TXV is used. When manu-factured, it is put into the remote bulb in a liquid state. Volume is controlled so that within the design tempera-ture range some liquid always remains in the bulb. Therefore, the power element pressure is always the saturation pressure corresponding to the temperature of the remote bulb.

IN IN

ININ

OUTOUT

OUTOUTBALANCED CAGE

ASSEMBLY

CONVENTIONALCAGE ASSEMBLY

Fig. 11Fig. a

Balance Ported Pin

Equal AreasEqual Forces

Inlet Pressure

Eliminates Imbalance Forces

Fig. b

10


As in liquid charges, the remote bulb can be filled with the same refrigerant as the system refrigerant (pro-ducing a gas charge). Or, it can be filled with a different refrigerant, producing a gas cross-charge.

Adsorption Charges

The final type of charge is adsorption. In adsorption, solids hold large quantities of gas, not by taking them into the body of the solid, as in absorption, but by gath-ering them and holding them on the surface of the solid without chemical reaction.

The vapor penetrates into the cracks and furrows of the solid, allowing far greater capacity than possible with absorption.

The advantage of an adsorption charge is that in a fixed volume, the quantity of vapor adsorbed varies with the temperature and the system. So it can be used to exert operating pressure as a function of temperature.

Typical adsorbents include: charcoal, silica gel, acti-vated alumina.

Liquid charges have the following properties:• Not subject to cross-ambient control loss• Little or no superheat at start-up• Superheat increase at lower evaporator temperatures• Slow suction pressure pulldown after start-up

REFRIGERANT CODE NAMES

ARI Standard 750-2007 recommends the following color coding of the TXVs:

R- White R- Green R-502 Orchid R-134a Light Blue R-410A Rose R-404A Orange R-507A Blue Green (Teal)

Liquid Cross-Charges

Liquid cross-charges means that the power element contains a liquid refrigerant different from the system refrigerant in which the TXV is used. The pressure tem-perature curve of the charge crosses the curve of the system refrigerant.

Liquid cross-charge advantages are: • Moderately slow pull down• Insensitive to cross-ambient conditions. • Damped response to suction line temperature changes (reduces tendency for TXV hunting) • Superheat characteristics can be tailored for special applications

Gas & Gas Cross-Charges

Using a gas charge in place of a liquid alters the operational characteristics, because gas is compress-ible. At some predetermined temperature, the gas in the remote bulb becomes superheated, limiting the force it exerts. This produces higher superheats at higher evap-orator pressures and is labeled the Maximum Operating Pressure (MOP) effect.

Any MOP point temperature depends on how that bulb was charged and where it will be used. All gas charges are susceptible to cross-ambient control loss when the power element is colder than the remote bulb. They respond faster, but tend to hunt for the proper operating level, so a ballast is often added to the remote bulb to reduce that tendency.

What happens with an adsorption charge

Which Charge to Use?

Here are some typical examples of applications by refrigerant charge:

Liquid ChargeIce makers, pilots, liquid injection valves

Liquid Cross-ChargesCommercial refrigeration (low & medium temp.), ice makers, transport refrigeration and air conditioning

Gas ChargeAir conditioning (including mobile), water chillers

Gas Cross-ChargeHeat pumps and air conditioning

MOP Maximum Operating Pressure


Other TXV Considerations

Solenoid Liquid Stop Valves

The TXV is produced as a tight seating device. But if the TXV is exposed to dirt, moisture, corrosion, and erosion the TXV will not be able to positively shut off. If the remote bulb is installed in a location where during the “off’ cycle it is influenced by a higher ambient tem-perature than the evaporator, the valve will open and ad-mit liquid to the evaporator. Installing a Solenoid Liquid Stop Valve ahead of any TXV is highly recommended.

Filter-Driers for System Protection

To protect the precision working parts of control valves from dirt and chips which can damage them and make them inoperative, and to protect the entire system from the damaging affects of moisture, sludge and ac-ids, a filter-drier should be installed on every system.

Pressure Switch Setting

On TXVs with M.O.P., a Pressure Switch must be set to cut in at a pressure lower than M.O.P. rating of the TXV.

Emerson TXVs

Emerson’s TXVs are designed for a wide range of air conditioning, refrigeration, heat pump, and chiller ap-plications. Emerson uses stainless steel power elements that will not corrode.

Emerson’s integral TXV line includes valves for com-mercial and refrigeration applications, and heat pump and residential applications. The “Take-A-Part Series” TXVs are available for almost any type of application, temperature range, or refrigerant. Emerson also offers a complete line of specialty TXVs.

Factory Superheat Setting

Unless otherwise specified, all Emerson TXVs will be preset at the factory at a bath temperature which is predetermined by the charge symbol or the MOP rat-ing. The bath temperature at which the TXV superheat is set is coded alphabetically in the superheat block on the TXV nameplate, as shown in Fig. 15.

Fig. 15

Degrees of SH Per TurnValve “Total R-22 R-134a R-404A/507A R-410AFamily Turns” +20°F -20°F +20°F +20°F -20°F +40°F

TCLE 32 0.8 1.5 1.0 0.5 1.0 N/A

HF 10 2.2 4.2 3.8 1.8 3.2 N/A

A 8 3.0 5.0 4.5 2.0 4.0 2

TRAE 10 2.2 4.2 3.8 1.8 3.2 N/A

C 12 – – – – – 4

TXV SUPERHEAT ADJUSTMENT

Turn adjustment clockwise to increase superheat, counter-clockwise to decrease superheat. To return to approximate original factory setting, turn adjustment stem counterclockwise until the spring is completely unloaded (reaches stop or starts to “ratchet”). Then, turn it back in one half of the “Total Turns” shown on the chart.

For example, a TXV with “10A” stamped in the name-plate superheat block is set for 10°F static superheat with a 32°F bath. A TXV stamped “10C” is set for 10° of static superheat with a 0°F bath.

When ordering a TXV for an exact replacement, specify the code letter and the superheat setting de-sired. When ordering for general stock, it is not neces-sary to specify either the superheat or the code letter, since the standard setting will cover most applications and minor superheat adjustments may be made in the field.


To help you match the correct charge to your specific application, see the TXV Charge Code Selector on the next page. Also provided here are some typical exam-ples of applications by refrigerant charge.

Liquid Charge – LIce makers, pilots, liquid injection valves

Liquid Cross-Charges – C, ZCommercial refrigeration (low & medium temp.), ice makers, transport refrigeration and air conditioning

Gas Charge – GAir conditioning (including mobile), water chillers

Gas Cross-Charge – CA, AAHeat pumps and air conditioning

Gas Cross-Charge – HAAHeat pumps and air conditioning

W(MOP)Maximum Operating Pressure

EMERSON EMERSON ASHRAE TRADE OR CODE CODE REF . NO . CHEMICAL NAME COLOR LETTER

R-12 Dichlorodifluoromethane WHITE F R-22 Chlorodifluoromethane GREEN H R-502 22/115 PURPLE R R-134a Tetrafluoroethane LIGHT BLUE M R-404A 125/134a/143A ORANGE S R-401A 22/152A/124 CORAL X R-507A 125/143A TEAL P R-410A 32/125 ROSE Z

ARI Standard 750-2007 recommends the following color coding of thermostaticexpansion valves: R-12 White; R-22 Green; R-502 Orchid; R-40 Red;

R-500 Orange. Uncommon refrigerants with no designated color should use Blue.

Refrigerant Code Names

Emerson “T” Series TXVs [except “W”-(MOP), G-(MOP) or GS-(MOP) gas charged types] may be installed in any location in the system. The gas charged type must always be installed so that the power assem-bly will be warmer than the remote bulb. The remote bulb tubing must not be allowed to touch a surface cold-er than the remote bulb location. If the power assembly or remote bulb tubing becomes colder than remote bulb, the vapor charge will condense at the coldest point and remote bulb will lose control.

For exact TXV selection (i.e., refrigerant tonnage, connections, equalizer style, cap tube length, adjust-ment and proper application, air conditioning, commer-cial, low temperature) refer to Emerson catalog.

Emerson MOP

The Emerson “W” charge can be supplied with the MOP feature if needed for system protection. This need rarely occurs in modern day refrigeration except such conditions as immediately after defrost or on gasoline driven compressors such as truck refrigeration.

For special applications, other charges may be used from time to time. For help in selecting a charge with Motor Overload Protection (if required by compressor manufacturer) see the table below and the TXV Charge Selector on page 13.

NOTE: MOP not available with Rapid Response Bulb.

APPLICATION R134a R22 R404A/R507A

COMMERCIAL MW35 HW65 *W65

LOWTEMP. MW15 HW35 *W45

* Add refrigerAnt code As follows: s = r404A, P = r507A

Superheat adjustment of “W–MOP” charged TXVs will change the MOP point. An increase in superheat setting will lower the MOP point and a decrease in su-perheat setting will raise the MOP.

THERMOSTATICCHARGE

The table above refers to the maximum dehydration tempera-tures when the bulb and TXV body are subjected to the same temperature. On A, L, C, Z, and X charges, 250°F maximum TXV body temperature is permissible (if the bulb tempera-ture) does not exceed those shown in the table.

NOTE: Emerson charges “A”, “C” and “Z” are liquid cross-charges.

REFRIGERANT L C Z G WMOP/CA X R134a 195 190 250 250 250 N/A R22 160 160 185 250 250 N/A R404A/R507A 150 150 170 250 250 N/A R717 N/A N/A 150 N/A N/A 200

TABLE1–Maximum Dehydration Temperature (in °F)

13


HW35

AIRCONDITIONING COMMERCIALREFRIGERATION LOWTEMPERATURE OLDCHARGE REPLACEMENT OLDCHARGE REPLACEMENT OLDCHARGE REPLACEMENT

REFRIGERANTR12/R134a FORFL — — FC FC — FW FW FWZ FG55 FC FG35 — — FW55 FW35 FW35 FW15 FQ55 FQ35 FW15 FGA FLA — — FGS FGS35 FGS35 FWS FWS FWS FWS FWS FWS FZ/MZ FZ/MZ FX FX

REFRIGERANTR22 HORHL — — HC HC — HW HCA HW HWZ HG100 HG65 — — HW100 HW65 HW65 HW35 HQ100 HC HQ65 HQ35 HGA HLA — — HW85 HW85 — — HGS HGS65 HGS65 HWS HWS HWS HWS HWS HWS HZ HZ HX HX

REFRIGERANTR502/R404A/R507A RL — — RW RC/SC/PC RW RWZ RZ RW110 RW65 RW65 RW35 RW45/SW45 RWS RWS RZ RZ/SZ/PZ

HZ HC

— —

FW15/MW15

RC/SC/PC

RWS RWS RWS RWS

FZ

TXV Replacement Charge Symbols Cross ReferenceOld Bulb Charges vs. New Replacement Bulb Charge

NOTE: ALL OTHER CHARGE SYMBOLS MUST BE REPLACED WITH AN IDENTICAL MODEL OR AT THE OPTION OF THE EMERSON TECHNICAL SERVICE DEPART-MENT WHO MAY MAKE ENGINEERING AUTHORIZED SUBSTITUTION OF EQUIVALENT TYPE TO PROVIDE EQUIVALENT OPERATION AND PERFORMANCE.NOTE: FOR FIELD REPLACEMENT PURPOSES, HC CAN BE USED TO REPLACE HCA.

TXV Charge Code Selector

Applications Operating Ranges

R-134a/R-12Domestic Refrigerators and Freezers, Ice Makers,Dehumidifiers,

Transport Refrigeration, Medium Temperature Supermarket Equipment,Medium Temperature Commercial Equipment

MC/FCMZ/FZ

MW15/FW15 (MOP)MW35/FW35 (MOP)

MW55

R-Residential Air Conditioners &Heat Pumps, Commercial and

Industrial Chillers, Medium Temperature Supermarket Equipment, Commercial Air Handlers

HCA/HAA AIR COND. & HEAT PUMPHW/HW100

HCHW65 (MOP)

HZ

R-404A/R-507A/R-502Low Temperature Cases, Ice Makers, Commercial Air Handlers,

Conditioners, Soft Ice Cream Machines, Environmental Chambers

SC/RCSZ/RZ

SW45/RW45 (MOP)R-410A ZW195

-50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50

142008

Solenoid Valves

15

Solenoid Valves

Direct Acting Solenoid Anatomy

What Are Solenoid Valves?

A solenoid valve consists of two distinct but integral acting parts, a coil and a valve. See drawing below for complete valve anatomy.

Solenoid Valves

In most refrigeration applications, it is necessary to start or stop the flow in a refrigerant circuit to automati-cally control the fluids in the system. An electrically operated solenoid valve is usually used for this purpose. Its basic function is the same as a manually operated shut off valve, but by being solenoid actuated, it can be positioned in remote locations and may be conveniently controlled by simple electrical switches.

Solenoid valves can be operated by a thermostatic switch, float switches, low pressure switches, high pres-sure switches or any other device for making or breaking an electric circuit, with the thermostatic switch being the most common device used in refrigeration systems.

Principles of Solenoid Operation

Solenoids are either direct acting or pilot operated. The application determines the need for either of these types. The direct acting valve is used on valves with low capacities and small port sizes. The pilot operated type is used on the larger valves, eliminating the need for larger coils and plungers.

1 . Direct Acting

In the direct acting type valve, as discussed under Solenoid Valve operation, the plunger is mechanically connected to the needle valve. When the coil is ener-gized, the plunger pulling the needle off the orifice is raised into the center of the coil. A direct acting valve will operate from zero pressure differential to its maximum rated pressure differential, regardless of the line pres-sure.

The direct acting type valve is only used on small capacity circuits because of the increased coil size that would be required to counter the large pressure dif-ferential of large capacities. The required coil would be large, uneconomical, and not feasible for large capacity circuits. To overcome this problem on large systems, pilot operated solenoid valves are used.

The coil is nothing more than electrical wire wound around the surface of a cylindrical form usually of circu-lar cross section. When an electric current is sent thru the windings, they act as an electromagnet. The force field that is created in the center of the solenoid is the driving force for opening the valve. Inside is a moveable magnetic steel plunger that is drawn toward the center of the coil when energized.

The valve contains an orifice through which fluid flows when open. A needle or rod is seated on or in the orifice and is attached directly to the lower part of the plunger.

When the coil is energized, the plunger is forced toward the center of the coil, lifting the needle valve off of the orifice and allowing flow. With a normally-closed valve, when the coil is de-energized, the weight of the plunger and in some designs, a spring, causes it to fall and close off the orifice, thus stopping the flow through

the valve. Less common are normally-open valves which are open when the coil is de-energized.

Enclosing TubeTop PlugAssembly

Return Spring

Plunger Assembly

Collar

BodyAssemblyO-Ring

Solenoid Valves

Figures 1A and 1B show a simple schematic of a Direct Acting Solenoid Valve in operation.

2 . Pilot Operated Valve

The pilot operated solenoid valve uses a combination of the solenoid coil and the line pressure to operate. In this type valve the plunger is attached to a needle valve covering a pilot orifice rather than the main port. The line pressure holds an independent piston or diaphragm closed against the main port. See figures 2a and 2b. When the coil is energized, the plunger is pulled into the center of the coil, opening the pilot orifice. Once the pilot port is opened, the line pressure above the diaphragm is allowed to bleed off to the low side or outlet of the valve, thus relieving the pressure on the top of the diaphragm. The inlet pressure then pushes the diaphragm up and off of the main valve port and holds it there allowing full fluid flow. When the coil is de-energized, the plunger drops and closes the pilot orifice. Pressure starts to build up above the diaphragm by means of a bleed hole in the piston diaphragm until it and the diaphragm’s weight and spring cause it to close on the main valve port. A pilot operated solenoid valve requires a minimum pressure difference of several pounds between inlet and outlet to operate.

Types of Solenoids

There are different types of solenoid valves for differ-ent applications. The three main types of valves are the 2-way, 3-way, and 4-way valves. The 2-way valve is the most common.

2-Way Valves

The 2-way valve controls fluid flow in one line. It has an inlet and an outlet connection. This valve can be of the direct acting or pilot operated type of valve depend-ing on the need. When the coil is de-energized, the -way valve is normally closed. Although normally closed is the most widely used, two-way and three-way valves are manufactured to be normally open when the coil is de-energized. See Figure 3 for an example of a 2-way valve.

Figures 2A and 2B show a simple schematic of a Pilot Operated Solenoid Valve in operation.

NOTE: 2-way valves are usually designed to have flow in one direction only. Some valves may be modified to have flow in both directions. A “bi-flow” kit must be used.

Figure 3

FIG. 1A DE-ENERGIZED

FIG. 1B ENERGIZED

FIG. 2A DE-ENERGIZED

FIG. 2B ENERGIZED

Solenoid Valves

Solenoid Valve Selection

The selection of a Solenoid Valve for a control ap-plication requires the following information:. Fluid to be controlled2. Capacity required3. Maximum operating pressure differential (MOPD)4. Electrical characteristics5. Maximum working pressure required (MWP)

The capacities of Solenoid Valves for normal liquid or suction gas refrigerant service are given in tons of refrigeration at some nominal pressure drop and stan-dard conditions. Manufacturers’ catalogs provide ex-tended tables to cover nearly all operating conditions for common refrigerants. Follow the manufacturer’s sizing recommendations. Do not select a valve based on line size. Pilot operated valves require a pressure drop to operate and selecting an oversize valve will result in the valve failing to open. Undersized valves result in exces-sive pressure drops.

The solenoid valve selected must have a MOPD rat-ing equal to or greater than the maximum possible differ-ential against which the valve must open. The MOPD or Maximum Operating Pressure Differential considers the inlet and outlet valve pressures. If a valve has a 500 psi inlet pressure and a 250 outlet pressure, and a MOPD rating of 300 psi it will operate, since the pressure dif-ference (or 500-250) is less than the 300 MOPD rating. If the pressure difference is larger than the MOPD, the valve will not open.

Minimum Operating Pressure Differential

Consideration of the maximum working pressure required is also important for proper and safe operation. A solenoid valve should not be used for an application when the pressure is higher than the valve maximum working pressure. Solenoid valves are designed for a given type of fluid so that the materials of construction will be compatible with that fluid. Special seat materi-als and synthetics may be used for high temperature or ultra-low temperature service. Special materials are required for corrosive fluids. Special attention to the electrical characteristics is also important. Required voltage and Hertz must be specified to ensure proper selection. Valves for DC service often have different in-ternal construction than valves for AC applications, so it is important to study the manufacturer’s catalog informa-tion. Solenoid valves should never be used as a Safety Shut Off unless specifically designed and rated for that service.

NOTE: No minimum pressure differential – valve will not operate.

NOTE: Pressure differential greater than minimum – valve will operate.

50 psig 50 psig 194 psig 200 psig

sP = 0 psig sP = 6 psig

Solenoid Valves

Installation

Solenoid Valves having a spring loaded piston or dia-phragm may be installed and operated in any position, but installing more than 90° from vertical is not recom-mended since dirt or debris may collect in the solenoid area and prevent it from operating. An adequate strainer or filter drier should be installed ahead of each solenoid valve to keep scale, pipe dope, solder, and other foreign matter out of the valve.

When installing a solenoid valve, be sure the arrow on the valve body points in the direction of refrigerant flow.

When brazing valves with extended solder type con-nections do not use too hot a torch and point the flow away from the valve. These valves do not normally need to be disassembled before installation; if the valve does not have extended connections, disassemble the valve before brazing. Wet rags or chill blocks are recom-mended during brazing. They are needed to keep the valve body cool so that body distortion on close-coupled valves will not occur. Allow the valve body to cool before replacing the valve’s operating insides to ensure that the seat material and gaskets are not damaged by the heat. When reassembling, do not over torque.

Application Overview

Application Product Family

Liquid, Suction Line Service 240RA/540RA or Hot Gas By-Pass 50RB 100RB 200RB/500RB Pressure Differential Valve for Gas Defrost 710RA 713RA

Emerson Solenoid Valves

Emerson offers a complete line of refrigerant solenoid valves for refrigeration and air-conditioning applications. As part of Emerson’s commitment to the industry, each valve undergoes stringent Emerson testing to ensure fail-safe operation. And, with the lowest external leak rates in the industry, Emerson solenoid valves ensure precise refrigerant flow, preventing system failures and aiding in environmental protection.

192008

System Protectors

20

System Protectors

Acid Pick-Up Capability

Various organic acids result during the decomposition of the refrigerant and oil in a system. This decomposition can be the result of moisture in the system, excessive temperatures, air, or exposure to foreign substances in the system. It is important that acid in a system is ab-sorbed as soon as it is formed to prevent the acid from causing system damage. Activated alumina is the most popular of the desiccants used to remove acid.

Tests have shown that the amount of acid and resin pick-up of an adsorbing agent is almost proportional to the weight of the desiccant. Size or granulation makes little difference.

There is no industry-approved method for rating acid removal. So weight of the desiccant provides the handi-est measure.

Wax Removal

The ability of a filter-drier to remove wax and resins is important in low temperature applications that use R-22. Wax when present in a system tends to solidify on valve seats and pins, resulting in system malfunctions.

Flow Rate

Published flow rates for filter-driers are established in accord with ARI Standard 710 for liquid line driers, and ARI Standard 730 for suction line driers.

Liquid line and suction line filter-driers are often referred to as System Protectors because they remove harmful elements from the circulating refrigerant before serious damage results.

Keeping the system clean and free of foreign con-taminants that can restrict the operation of valves, block capillary tubes or damage compressors is the best way to assure trouble-free operation. These contaminants can be solids, such as metal filings, flux, dust and dirt. Other equally menacing contaminants are solubles, such as acid, water, resins and wax.

No matter how many precautions are taken during assembly and installation or servicing of a system, contaminants can find a way into the system. Filter- driers are designed to protect a system during operation. It is the function of this all important unit to remove those residual elements that can attack and eventually destroy the system components.

Filtration Capacity

Solid particles or semi-solids such as sludges circulating in a refrigerant system can destroy valve seats, plug control valves, and score cylinder walls or compressor bearings. These contaminants can be the result of manufacturing, servicing, or can be generated during normal system operation.

It is important to remove these contaminants as quickly as possible and prevent them from returning to the system. Properly specified filter-driers are designed to trap and hold large quantities of these contaminants while maintaining low pressure drop during their service life.

Moisture Capability

Moisture in a refrigeration system can cause frozen valves, copper plating, damaged motor insulation, corro-sion, and sludges. Filter-driers remove and retain mois-ture through one or more desiccants. The most popular and effective desiccant in use today for the removal of moisture is molecular sieve which can hold three to four times the water of other commercial absorbents.

Moisture capacity of a filter-drier is normally given in drops of water per ARI Standard 710. These rated capacities are in addition to any residual moisture that might be absorbed during manufacturing.

MWP-680

System Protectors

Compacted bead style filter-drier, Emerson’s EK-Plus

Absorption vs . Adsorption

One factor to consider in selection is ab- vs. ad-sorption. Absorption means a material’s ability to take another substance into its inner molecular structure.

An adsorbed substance doesn’t penetrate the mo-lecular structure. It simply starts building up on the sur-face of the adsorbent. Walls, cracks, crevices are part of the surface area and are able to hold other substances, greatly increasing capacity.

Modern desiccants are extremely porous and have a large surface area and internal pore volume of a size and shape to adsorb and retain water molecules.

Types of Filter-Driers

All the liquid line filter-driers on the market today are a variation of one of two types: the molded core type or the bead type.

Molded core type filter-driers are manufactured by mixing desiccants (which remove the soluble contami-nants) with a bonding agent, then baking them to give them permanent shape and to activate the drying ingre-dients. The results is a porous core which acts as filter and drying agent.

Compacted bead style filter-driers are manufactured with the active desiccant in bead or pellet form; no bond-ing material is used. Rather, compacting comes from mechanical pressure exerted by a spring. Compacted bead-style filter-driers usually include an additional filter network to trap solid contaminants from the refrigerant, unlike most core styles.

The separate and distinctive filter media can take various forms that permit depth filtration with greater solid contaminant capacity and contaminant retention during start-up and shutdown when turbulent condi-tions exist.

Compacted bead filter-driers offer the maximum vol-ume of desiccant because filtering and drying is done in one mass. But, because the core is porous, it does not hold all solid contaminants; often particles are washed through channels within in the core when pressures surge. Better holding power is possible with a more compacted core. But pressure drops increase inversely.

Fig 1. Proper placement of filter-drier in the system

Dirt, Waxes, Acid

Every system has contaminants in it as soon as it is opened. These contaminants may be insoluble, such as metal filings not removed in manufacturing, or airborne dirt that entered when the system was opened. Or they may be soluble, such as waxes, acids, water and resins that develop through reactions between air, the refriger-ant, or lubricant.

Any of these can cause system failure. Installing an all-purpose filter-drier can lessen chances for trouble.

There are basic differences to consider: type of filter, how it filters, and its true capacity.

Most manufacturers rate their filters to ARI Standard 710. But even though two clean filter-driers may be rated the same, there can be a vast difference in flow as the quantity of solids picked up increases.

System Protectors

Refrigerant Water Concentration (ppm)

0

0.05

0.1

0.15

0.2

0 100 200 300 400 500 600 700

Tota

l Aci

d N

umbe

r

HFC Refrigerants and POE Lubricants

The use of HFC refrigerants and Polyolester (POE) lubricants for air-conditioning and refrigeration has generated new system chemistry related problems. New and redesigned system protectors have been developed to counter these problems and provide a long, reliable life for the operating refrigeration system.

Moisture is the major problem causing contaminate for HFC/POE oil systems just as it was for CFC and HCFC systems using Mineral oil. Many HFCs can hold much more water than their CFC counterparts but the oil differences are much worse than those of the refriger-ant. POE oil can hold as much as 10 times more water than Mineral oils. Evacuation alone has proved ineffec-tive at removing this moisture so a filter-drier is required to perform this function.

Water poses a new problem for POE oils above and beyond those experienced with Mineral oil. POE oil will react with water to form organic acids at normal operat-ing conditions in refrigerating and air-conditioning sys-tems. This reaction starts at water levels as low as 75 ppm. These acids attack system components including motor insulation and metallic parts, reducing system life.

To combat the detrimental effects of water in HFC and POE oil systems it is imperative to hold moisture levels as low as possible. Water level must be main-tained less than 50 ppm in the refrigerant and the same for the oil.

Figure

Acid Generation in a 1.5 Ton POE Oil Containing System

Another aspect of POE oil is the ability to keep more solid particles in suspension than Mineral oil. This is important in retrofitted systems where pockets of solid contamination are now flushed from low flow areas and need to be removed before moving parts in the system are damaged. The filter-drier for POE oils needs to have higher solid particle holding capacity with little impact to refrigerant flow capacity or pressure drop.

The filter-drier should also have improved contami-nate removal efficiency as well to ensure that all par-ticles are captured the first time they enter the filter-drier. The ability to remove smaller particles is also advanta-geous. The Emerson EK series filter-driers provide a unique combination of these characteristics to provide outstanding filtration as shown in Figure 4.

0

25

50

75

100

125

75 100 125

HMI

TypicalSightglass

R-134a Refrigerant Temperature

Moi

stur

e Le

vel (

ppm

)

Figure 3Dry Indication Water Level

0

500

1000

1500

2000

2500

Water Content (ppm)

MineralOil

POE Oil R-12 R-134a R-22 R-502 R-404A R-410A

23

System Protectors

EKTypical drier

Solid Contamination Captured

Flow

Res

tric

tion

The filter-driers for use in HFC and POE oil systems must maintain the system dry and free of any acids gen-erated. However, since water capacity is of primary im-portance the filter-drier should contain a higher percent-age of molecular sieve than was required for CFC and HCFC systems. But molecular sieve alone is not enough since it has almost no organic acid capacity. An organic acid removal desiccant must be used such as activated alumina to ensure low acid levels are maintained. The filter-drier should also have higher filtration capacity and efficiency. The EK series of filter-driers provides the best combination of these properties to ensure the long, trouble-free life of any air-conditioning or refrigeration system.

The moisture indicating sightglass must also indicate moisture levels less than 50 ppm moisture. Also, it must be able to perform this function at the temperature of the liquid line on which it is placed. Many sightglasses can-not perform this function at all liquid line temperatures. This low level indication ability is needed to ensure that the system moisture never exceeds the level at which organic acid formation starts. The Emerson HMI mois-ture indicating sightglass provides this low level detec-tion ability.

Figure 4Filtration Capability of Filter-driers

Emerson ASD suction line filter-drier

Suction Filter-Driers

The function of filter-driers in refrigeration and air conditioning systems is to trap moisture and harmful contaminants. But their use in the liquid line still tends to be thought of as the “standard” application; including them also in the suction line hasn’t yet become stan-dard practice to the same degree.

A filter-drier in the liquid line essentially protects the system controls – solenoid valves, expansion valves, and pressure regulators. The function of the filter or filter-drier in the suction line is specifically to protect the compressor against contaminants.

Such protection is encouraged by compressor manu-facturers in any case, but there are two circumstances that make suction line filters or filter-driers advisable.

Field Built-up Systems

It is practically impossible to avoid contamination when assembling a refrigeration system in the field. Dirt, moisture, metal particles, and copper oxide from braz-ing all can be present in the system despite the greatest care, and all can damage are reduce the service life of the compressor.

In large and complex systems, such as a single system serving several food cases throughout a super-market, it is a generally accepted practice to install a cartridge-type filter in the suction line. Then, because of the virtual certainty of contamination during assembly of the system, the initial cartridge is removed and replaced after the first few days of system operation.

When considering the price of a compressor, the cost of protecting it with a suction line filter is insignificant.

24

System Protectors

Cross-section shows desiccant beads surrounding accordion-type filter element

Typical system arrangements show suction line filter-drier installed ahead of the compressor.

Internal Design

Internally, suction line filter-driers employ the same types of elements as liquid line units. One is the core type, in which the filter-drier consists of a rigid, cylindrical, porous core that may perform both the filter and drier functions, or be used in combination with a separate accordion-type filter element.

The core type filter-drier is available either in a hermetically sealed configuration or in take-apart designs with a replaceable element.

The latest advancement is the bead-type unit, in which the desiccant is compacted into the shell. This design offers several advantages over older types, including lower pressure drop, more desic-cant surface area, and greater capacity.

Application Tips

Using a liquid line filter-drier as a suction line filter-drier is not recommended. A suction line filter-drier should provide for greater capacity than a liquid line unit, for better compressor protection and for less pressure drop. Two access valves are required to measure pressure drop across the suction line filter-drier.

25

System Protectors

Clean-Up Procedure for Compressor Motor Burnout

1. Determine the extent of the burnout. For mild burnouts where contamination has not spread thru the system it may be economical to save the refrigerant charge, if the system has service valves on the compressor. A severe burnout exists if the oil is discolored, an acid odor is present, and contamination products are found on the high and low side. In this condition, caution should be exercised to avoid breathing the acid vapors. Also, avoid skin contact with the contaminated liquid.

. Thoroughly clean and replace all system controls such as TXVs, solenoids, check valves, and reversing valves. Remove all strainers and filter-driers.

3. Install replacement compressor and make a complete electrical check.

4. Make sure that the suction line near the compressor is clean. Install an over-sized liquid line filter-drier and a suction line filter-drier.

5. Pressure and leak-test the system according to unit manufacturer’s recommendations.

6. Triple evacuate to at least 200 microns. Break the vacuum with clean, dry refrigerant at 0 psig.

7. Charge the system through an Emerson EK filter-drier to equipment manufacturer’s recommendations.

8. Start the compressor and put the system in operation. Record the pressure drop across the suction line filter-drier on the enclosed label and apply label to the side of the shell.

9. Replace the suction line filter-drier if the pressure drop becomes excessive.

10. Observe the system during the first 4 hours. Repeat step 9 as often as required, until no further change in pres-sure drop is observed.

11. After the system has been in operation for 48 hours, check the condition of the oil with an acid test kit. If the oil test indicates an acid condition, replace the liquid and suction line filter-driers.

12. Check the system again after 2 weeks of operation. If the oil is still discolored, replace the liquid and suction line filter-drier.

13. Clean-up is finished when the oil is clean and odor-free, and is determined to be acceptable with the acid test kit.

For detailed burnout clean-up procedure and recommendations, consult the RSES Service Manual, Section 91.

Compressor Burnout

A compressor burnout can be expected to release a variety of pollutants into the system, including acids. The clean-up procedure below describes the use of system protectors in cleaning up a system.

System Protectors

Schematic of a basic heat pump system.

Filter-Driers for Heat Pumps

A heat pump is essentially a refrigeration sys-tem that can flow in either direction. The key to its operation is a four-way reversing valve that routes the discharge gas from the compressor.

Depending on whether the system is cooling or heating, the indoor and outdoor coils swap roles, taking turns serving as the condenser and evapo-rator.

Since conventional refrigerant control compo-nents are designed for unidirectional operation, their use in heat pumps requires installation in pairs, one for each direction, with check valves routing the flow through or around them. Today, because of the growing use of heat pumps, com-ponents such as thermostatic expansion valves are available in bi-directional versions, as are filter-driers.

Removing Contaminants

Just like any other refrigeration system, heat pump system components need filter-drier protec-tion to remove solid and soluble contaminants. This may be handled several ways.

First, in systems with one-way expansion valves and check valves, a one-way filter-drier might be installed in series with a check valve. This would be a “part-time” arrangement, in that filtration would be provided in only one direction.

Second, a one-way filter-drier might be in-stalled with each of the check valves, so that one provides filtration in each direction.

Third, the simplest arrangement is to install a bi-directional filter-drier in the common liquid line. Used in combination with a bi-directional thermo-static expansion valve such as Emerson’s HF se-ries, the complexity of multiple expansion valves, check valves, and filter-driers can be completely eliminated.

Emerson BKF bi-directional pump filter-drier

One-Way Flow, Both Ways

Inside a bi-directional filter-drier the refrigerant always flows the same direction regardless of which way the refrigerant is flowing through the system. The internal flow in this case is controlled by an inlet flapper valve and an outlet poppet valve on each side of the desiccant core. As the liquid enters the filter-drier from either direction, the inlet flapper valve routes it to the outside of the desiccant core. After it flows through to the inside of the desiccant core, it exits through the op-posite poppet valve.

The purpose of the arrangement shown below is to prevent contaminants collected in one direction from be-ing flushed back out when the flow reverses.

System Protectors

Bi-directional components allow simplification of system

Cross section showing BFK internal componentsSimplifying While Servicing

When servicing or repairing heat pump systems, especially older units, it’s a good idea to simplify them by replacing unidirectional driers and check valves with bi-directional driers. When a bi-directional filter-drier is installed, check valves, and filter-driers can all be replaced at once with copper tubing.

Refrigerant flow either direction passes from outside to inside of desiccant core

Emerson System Protectors

Emerson filter-driers were redesigned for increased water removal capacity to reach these low moisture levels. However, since no system is entirely without water on startup some organic acids will be generated and must be removed. The desiccant formulation for the Emerson EK series of filter-driers was designed to provide the best mix of water capacity and acid capacity to ensure that harmful contaminates are removed. This desiccant mixture contains molecular sieve and activat-ed alumina. The molecular sieve is specifically designed to provide maximum drying in today’s systems. The activated alumina is ideal for capturing the large organic acids that the molecular sieve cannot.

Replace two check valves and twoexpansion valves with one EMERSONBi-directional Thermal Expansion Valve

Expansion Device

Filter-Drier

Check Valve

Check Valve

Filter-Drier

Expansion Device

Remove both filter-driers &replace each with a piece of

copper tube

Install One BFKin a convenientLocation in CommonLiquid Line

EmersonSuction LineFilter-Drier

EmersonDischargeMuffler

Emerson 4-wayReversing Valve

Compressor

Molded Desiccant Block InletFlapperValve

OutletPoppertValve

OutletPoppertValve

InletFlapperValve

InletFlapperValve

InletFlapperValve

Steel Retaining ScreenSteel Retaining Screen Final Filter Pad

INTERNALCONSTRUCTION

BASIC FLOWPATTERNS

HeatingCycle

CoolingCycle

2008

Regulators

29

Regulators

EVAPORATORPRESSUREREGULATOR EVAPORATOR

PRESSUREREGULATOR

EXTERNALSTRAINERRECOMMENDED

NOTE: HIGH SIDE PILOTPRESSURE REQUIRED

FOR EPRBS

NOTE: HIGH SIDE PILOTPRESSURE REQUIRED

FOR EPRBS

EXTERNALSTRAINERRECOMMENDED

60 PSIGHIGH

EVAPORATORPRESSURE

50 PSIGINTERMEDIATEEVAPORATORPRESSURE

20 PSIGLOW

EVAPORATORPRESSURE

Types of Regulators:Suction Line Regulators

Suction line regulators provide a wide variety of re-frigerant control functions, but are mainly used for regu-lating suction gas pressures. These regulators provide a method of balancing the output of the refrigeration system with the load requirements. Two basic types are covered here:1) Upstream pressure regulators, which control from an inlet pressure signal.2) Downstream pressure regulators, which control from an outlet pressure signal.

Application of Evaporator Pressure Regulators

Evaporator Pressure Regulators are normally used on multiple-compressor refrigeration systems fed by TXVs, low side floats or solenoid liquid valve and float switch combination. They are used whenever a mini-mum evaporator pressure or temperature is desired. Controlling from an inlet side pressure signal, they prevent upstream pressure from going below a pre-set point.

EPR valves are used on brine or water chillers to pre-vent freeze-up during low load periods, by keeping the refrigerant saturation pressure above the fluid freezing temperature. Similarly, they may be used to prevent frost formation on fan coil evaporators. They may also be used to provide a given evaporator saturation pressure to produce the required evaporation/room temperature difference, (especially useful where humidity control is required). On multiple evaporator systems where differ-ent evaporator temperatures are required, EPR valves will hold the saturation pressure at the required set point above the common system suction pressure. Here, the EPRs prevent lowering of the desired temperature in the warmer evaporators, while the compressor continues operating to satisfy the coldest evaporators. See figure 1.

Figure 1: Evaporator Pressure Regulators used in multiple system.

EPR Installation

EPRs may be installed at the compressor rack or close to the evaporator.

Suction line regulators can be direct acting or inter-nally piloted such as an Emerson IPR regulator. These are hermetically sealed, non-repairable valves for use on low capacity systems.

For higher sensitivity and accurate control, an exter-nally piloted EPRB regulator will provide control of larger units. These are repairable in the line. The EPRB valve is a lightweight, brass body valve which eliminates the need for normal system pressure drop needed to make the valve move through the full stroke. This is accom-plished by using compressor discharge gas to pilot the regulator.

Combining an EPRB with a suction stop or shut off is done with the EPRBS models. When the pilot solenoid is de-energized, the valve closes. This eliminates the cost of a separate suction solenoid and offers a tight shut off.

Figure 2: Cutaway view of an EPRBS.

30

Regulators

Upstream Regulators

The sole function of the Evaporator Pressure Regu-lator is to prevent the evaporator pressure from falling below a predetermined pressure setting. This enables the system to meet certain load requirements over a wide range of conditions and offers improvement over the simple “on-off” compressor control usually provided by thermostats or pressure switches.

Downstream Pressure Regulators

Suction pressure regulators are used to prevent compressor motor overload. By throttling the suction gas flow during high load conditions, the compressor motor is permitted to remain within current draw limitations. Often referred to as holdback valves, crankcase pres-sure regulators or suction pressure regulators, they also serve many other useful applications.

A downstream pressure regulator can be direct acting such as an OPR valve. These are hermetically sealed, non-repairable outlet pressure regulators for use on low capacity systems.

Figure 3: EPRB(S) Brass Body Upstream Pressure Regulator with Suction Stop Option

Valve Adjustable Range EPRB(S)-12 thru -20 0 to 110 psig 0 to 50 psig IPR-6, -10 30 to 100 psig 65 to 225 psig 0 to 60 psig OPR-6, -10 50 to 130 psig 100 to 225 psig

Adjustable Range Table

Voltage Cycles 24 120 50-60 Hz, AC 208-240

Standard Voltage & Frequencies Table

Series EPRB & IPR

These are all upstream regulators which can be selected from the capacity charts available. Combin-ing the regulator with a suction stop or shutoff solenoid will cause the regulator to act as a suction stop valve. Certain basic design operating condition data must be determined to properly apply the regulator. For best results, follow the simple procedure outlined below.

To select the proper regulator port size, the following information is required:1. System refrigerant (R134a, R22, R404A/R507A). 2. The required pressure setting (lowest allowable

evaporator pressure and corresponding refrigerant saturation temperature).

3. The system suction pressure at the regulator outlet (suction pressure where compressor capacity bal-ances with system load) making allowance for any common suction line pressure drop.

4. Pressure drop across regulator port. Subtract suction pressure (3) from regulator set point (2).

5. Evaporator load in tons at regulator setting (required minimum evaporator saturation temperature).

With the above information, select the proper regula-tor as follows:. Select the valve extended capacity table from that

page which covers the system refrigerant.2. Find the required evaporator saturation temperature

column.3. For the available regulator pressure drop, find the

rated capacity for each regulator port size.4. Select the proper port size from the capacity which

matches the evaporator load.

31

Regulators

Fig 4. Cutaway of crankcase pressure regulator (Emerson OPR)

Fig 5. Cutaway of evaporator pressure regulator (Emerson EPRB).

Crankcase Regulators

Normally open, the CPR (Fig. 4) closes when com-pressor pressure rises above the pre-set maximum, forcing the valve back onto its seat. As suction pressure drops, the valve starts to reopen, maintaining a balance.

Where to Apply Regulators

EPRs are most commonly used on multiple evapo-rator systems, installed in the branch lines close to the required control source. They are used for indirect temperature control. They also maintain evaporator pressure during defrost, conserving power, expediting the defrost and reducing flood back.

CPRs are usually only applied if the system is being continually “over-pressured,” causing the compressor to be overloaded. If you suspect that’s the case, check the amp draw on the compressor while it’s running. If it’s higher than the plate rating, the system may be a CPR candidate.

How to Apply Regulators

It isn’t normally necessary to apply both an EPR and a crankcase regulator. Most installations only utilize an EPR.

Typical installations of EPRs are in supermarket systems, large chillers, and industrial processes where large amounts of heat must be absorbed. Smaller (including residential) systems of less than 5 tons are usually equipped with compressors designed to operate well within 30°-40°F variations.

One of the advantages of suction line regulators in supermarkets is that by adding EPRs you can control the operating temperatures of the individual cases in a single loop system.

32

Regulators

HeadMaster Head Pressure Controls

The application of air-cooled condensers for year-round operation, or during periods of low ambient temperature, requires some means of control to main-tain adequate condensing pressures that ensure proper system performance. It is essential that proper liquid refrigerant pressure be controlled to:1) Maintain liquid subcooling and prevent liquid line

flash gas.2) Provide adequate pressure at the inlet side of the

Thermostatic Expansion Valve to get enough pres-sure drop across the valve port.

3) Properly operate systems with hot gas defrost or hot gas bypass.

4) Provide adequate temperature for operation of heat reclaim systems.

Without proper control of condensing pressure a refrigeration system might not perform properly and components can be damaged. Emerson’s HeadMaster Control offers an efficient and economical approach to this common industry problem on air cooled condensers.

The HeadMaster 3-Way Head Pressure Control eliminates the need for special piping or multiple con-trol valves. As a single unit it simplifies piping and cuts installation costs.

HeadMaster HP Operation

The HP control is a three-way modulating valve controlled by the discharge pressure. The charged dome exerts a constant pressure on top of the diaphragm. At high ambient air temperature, bypass gas entering Port B is allowed under the diaphragm where it counters the pressure of the dome charge. This upward push on the diaphragm allows the seat disc to seal against the top seat, preventing flow from Port B (discharge gas) while flow from Port C is unrestricted (see figure 6).

Figure 6: HeadMaster HP Valve CutAway View

As ambient air temperature falls, an uncontrolled air cooled condenser will exhibit a corresponding decrease in head pressure. As the discharge (bypass) pressure falls, it no longer counters the dome charge pressure and the diaphragm moves downward, moving the push-rod and seat disc toward the bottom seat. This allows discharge (bypass) gas to be metered into the receiver, creating a higher pressure at the condenser outlet. The higher pressure at the condenser outlet reduces the flow from Port C and causes the level of condensed liquid to rise in the condenser.

The flooding of the condenser with liquid cuts the available condensing surface. The result is to raise the pressure in the condenser and maintain an adequate high side pressure. Figure illustrates a typical appli-cation of the 3-way control valve. This system is per-haps the most economical and reliable way to control discharge pressure. The three-way valve as shown in figure 6 is a fixed, non-adjustable valve. The wholesaler replacement setting is normally furnished for a pressure corresponding to 95° to 98°F condensing temperature for the given system refrigerant.

Figure 7: Typical 3-Way Valve Head Pressure Control Application

As with all head pressure control applications, addi-tional liquid receiver capacity is required to prevent loss of a liquid seal in the receiver when the condenser is flooded. The receiver must be large enough to hold the total system charge. The total system charge consists of the following:1. An operating charge which is the amount of refriger-

ant needed to operate the system during summer (high ambient temperature) conditions.

2. An additional charge equaling the amount of refriger-ant required to flood the condenser with liquid. The condenser must be filled with liquid to a point where a minimum head pressure is created for cold weather (low ambient temperature) conditions.

33

Regulators

NOTE: Should the outdoor temperature fall below de-sign conditions, more refrigerant will be required.

The total above is the total charge needed for satis-factory system performance during the lowest expected ambient air temperature conditions. During summer operation the receiver must be sized to safely hold the total system charge. Good refrigeration practice states that the total system charge should not exceed 80% of the receiver capacity.

CAUTION:1. The HP control should not be used on a system

which does not have a liquid receiver or on one with a receiver which is too small. If the receiver does not have adequate storage space, the refrigerant will back up in the condenser to produce excessively high discharge pressures during high ambient air tempera-tures, with could cause system damage or personal injury.

2. The HP control should be used only on systems which employ a Thermostatic Expansion Valve.

Installation of HP HeadMaster Series

Head pressure control systems are used on refrig-eration systems that are temperature operated. The compressor is started by a thermostat or the system operates on a pump down cycle, where the thermostat controls the liquid line solenoid valve and the compres-sor starts on a rise in suction pressure with a low pres-sure switch.

On systems that are pressure operated, migration of the refrigerant to the cold condenser on the “off” cycle should be prevented. If the system does not oper-ate on a pump down cycle, migration can take place through some compressors, from the suction line to the condenser. Crankcase heaters will prevent liquid from condensing in the crankcase, but will not stop migration to the cold condenser. If the system is properly charged, the filled condenser will permit the excess to remain in the receiver and low side.

Under some conditions where the receiver is located in a warm ambient, a check valve in the liquid drain line between the HeadMaster control and the receiver may be required to prevent the liquid receiver pressure from equalizing to that of the condenser during the “off” cycle. This enables the system to start on a pressure switch. Some systems may require a time delay on the low pressure switch. Condenser fans should not be cycled when using the HeadMaster control. The sudden chang-es in high side pressure caused by fan cycling will result in erratic Thermostatic Expansion Valve performance, and shortened head pressure control life. To prevent this

from happening, make sure fan controls are set to oper-ate at pressures above the HP valve setting.

HP Series Capacity & Selection

The nominal HP control capacity in tons for various refrigerants is shown in Table 1 for R134a, R22 and R404A/R507A. The nominal capacity is based on 100°F liquid, 40°F evaporator and the pressure drop shown. To get capacities in tons at other liquid and evaporator conditions, multiply the nominal capacity at the desired pressure drop by the correction factor given in the catalog for the liquid temperature and evaporator temperature.

Pressure Drop – PSI Valve Refrigerant 1 2 3 4 5 HP-5 2.0 2.9 3.6 4.1 4.6 HP-8 R-134a 5.5 7.8 9.6 11.0 12.4 HP-14 14.0 19.8 24.2 28.3 31.7 HP-5 2.2 3.2 3.9 4.5 5.0 HP-8 R-22 6.0 8.5 10.5 12.0 13.5 HP-14 14.7 20.8 25.6 29.7 33.8 HP-5 1.5 2.1 2.6 3.0 3.3 HP-8 3.9 5.5 6.7 7.8 8.7 HP-14 10.1 14.3 17.6 20.5 23.0

Based on 100°F liquid and 40°F evaporator

Table 1 – Nominal Capacity (tons)

R-404A R-507A

NOTE: Not recommended for systems utilizing patented sub-cooling coils in conjunction with low head pressure systems or on sytems where the condensate line bypassses the receiver in order to maintain subcooling effect in the liquid line.

NOTE: Do not select a valve for a capacity rating ex-ceeding 5 psi pressure drop from Port C to Port B or for a system with more than 20 psi pressure drop across the condenser.

During normal ambient conditions, the available liquid subcooling in the condenser will be adequate to cover the pressure drop through the HeadMaster control.

If a valve is selected for a given flow rate, the result-ing pressure drop must not cause the liquid pressure to drop below saturation and produce flash gas. If enough sub-cooling is not available to cover this pressure drop, it is suggested that more than one valve be installed in parallel to lower the pressure drop to tolerable limits.

Do not parallel valves of different capacities. Liquid drain lines from the condenser to receiver are sized for a velocity of 150 ft./min. or less.

34

Regulators

HP Parallel PipingHot Gas Bypass

Demand continues to mount for improved comfort conditioning combined with lower operating costs. New architectural designs have created real problems for contractors and engineers to maintain humidity con-trol at reduced loads, and to control load variations. Refrigeration and air conditioning systems are usu-ally designed to provide a given capacity at maximum conditions. These operate with little fluctuation through-out a narrow load range. However, only the larger size machines make any provisions for operation at reduced capacity. In some systems, integral cylinder unloading, gas engine drives with variable speed control, or even several smaller systems, provide a logical solution.

Function – Hot Gas Bypass Method

Many manufacturers now recommend use of a modulating control valve to provide a metered flow of compressor discharge gas to the system low side, in a proportion that will balance the system capacity to the load demand. This is commonly known as the hot gas bypass method. It permits full modulation of capacity on all types of reciprocating compressors, and extends capacity reduction below the last step of cylinder unload-ing.

The system must provide a means of bypassing high pressure refrigerant to the system low pressure side, to maintain operation at a given minimum suction pres-sure. Proper bypass control can be accomplished by a modulating type pressure regulator, which opens on a decrease in valve outlet pressure.

Operation of Bypass Valves

Bypass pressure regulators are grouped into the fol-lowing categories:1. Direct acting conventional port valves (figure 3)2. Direct acting balanced port valves (figure 4). Any of

these regulators are available with either an adjust-able setting, or a fixed, non adjustable setting.

Figure 4: Balance port CPHE adjustable field-serviceable hot gas bypass regulator.

Additional Refrigerant

On most systems, an added refrigerant will be re-quired. It is essential to have enough to completely fill the condenser for the lowest ambient condition. To accu-rately determine the added refrigerant charge required to fill the condenser, find the total length of condenser tubing in feet, and multiply by pounds of refrigerant per foot for a given size tubing.

Factory Settings

The HeadMaster Control is factory-set to provide an average condensing temperature consistent with good system performance. The complete type number includes the service reference code, port size, connec-tion size and style. When ordering, be sure to specify the complete type number.

UL File No . SA5312CSA File No . LR44005

Figure 3: DGRE adjustable hot gas bypass regulator.

35

Regulators

Figure 7: Direct acting hot gas regulator admitting flow between TEV and venturi distributor.

Applications: Hot Gas Bypass to Compressor Suction Line

Figure 6 shows the most common hot gas bypass system. In this system, the bypass line is taken directly from the compressor discharge line, through a bypass regulator, and into the suction line at the compressor. Although the hot gas bypass regulator is considered a downstream control, there is a big difference in function between a Crankcase Regulator and a hot gas regulator.

Pilot operated bypass valve main regulators have a long stroke stem with a restrictor plug characterized by either a parabolic or vee port restrictor plug design. This prevents the valve from operating close to the seat where pressure differential unbalance may occur, elimi-nating the need for a balanced port design.

The characterized port will provide smooth bypass flow modulation. Pilot operated valves usually have the extra features of a manual opening stem for testing or emergency operation, flanged connections, synthetic tight seating seats, and replaceable parts. Hot gas bypass valves can be applied to a system in several ways, differing only in the point to which the hot gas is to be bypassed. Several mixing methods are available. The one recommended is piped so that discharge gas is admitted to the suction line to flow against the direction of the suction gas as in figure 6.

Applications: Bypass to Evaporator Inlet

Another method is to bypass the hot discharge gas to the evaporator inlet, usually between the Thermal Valve and the refrigerant distributor (see figure 7). This pro-vides distinct advantages. The artificial load imposed on the evaporator causes the Thermal Valve to respond to the rise in superheat, eliminating the need for the liquid injection valve. The evaporator serves as an excellent chamber to provide homogeneous mixing of the gases before reaching the compressor.

Hot gas bypass into the evaporator is suggested when the evaporator elevation is below the compres-sor, to prevent oil trapping caused by low velocity at low loads. This assures proper oil return. Although there are many advantages to this system, it is not used on a multiple coil system, or where the evaporator sections may be located a distance from the compressor. The coil should be a free draining circuiting design to prevent the increase in velocity, due to forcing a large quantity of trapped liquid out of the low side, which in some cases may have enough volume to flood the compressor crankcase. Separate regulators must be used for each evaporator when bypassing to multiple evaporators located below the compressor to help oil return.

Figure 6: Hot gas bypass using type LCL liquid injection valve.

liQUidinJection

solenoid VAlVe

Bypass to flooded evaporators and suction line accumulators also present special cases. Contact the equipment manufacturer or the bypass control valve manufacturer for specific, detailed information.

Solenoid Valve for Positive Shut-off & Pump-down Cycle

It is recommended that a solenoid valve be installed ahead of the bypass regulator. This permits the system to operate on an automatic pump-down cycle.

36

Regulators

Thermal Valves for Liquid Injection

When hot gas is bypassed directly into the suction line, it is necessary to make some provision for desuper-heating the gas returning to the compressor. Without a small Thermal valve to lower suction gas temperature to tolerable limits, compressor damage may occur. Stan-dard Thermal Valves cannot be adjusted for control over 20°F superheat and, therefore, are not recommended. Liquid Injection Thermal Valves with special adjustment ranges are used to conform to compressor manufacturer temperature recommendations.

To simplify selection, Emerson has developed Liquid Injection Thermal Valves with four basic adjustment ranges. These are designated as models A, B, C and D. The adjustable superheat range chart (page 11) shows the proper power assembly charge symbol suffix for a given saturated suction temperature and a given super-heated suction gas temperature entering the compres-sor.

Nearly all Thermal valves for liquid injection may be internally equalized. However, if pressure drop occurs at the valve outlet due to a distributor, spray nozzle or other restrictive device, externally equalized valves may be needed.

Model LER and LIR valves are furnished with a 1/4” SAE male flare external equalizer as standard. Other models must include the code letter “E” to specify the 1/4” SAE male flare external equalizer connection. Example: LCLE and LJLE.

Application and Installation

Liquid injected into a gas to be desuperheated should be injected in a way which provides a homogeneous mixing of the liquid and superheated gas. Desuperheat-ing hot gas bypass in the suction line may be accom-plished in several ways.

The preferred method is to bullhead the hot gas and liquid injection in a tee to permit good mixing before it enters the suction line. A good mix with the suction gas may be gained by injecting the liquid/hot gas mixture into the suction line at a 45° angle against the flow of suction gas to the compressor. See figure 6.

For suction lines 7/8” OD and smaller, the bypass mixture may be introduced into a tee rather than an angle connection. For lines larger than 2-5/8” OD, intro-duce the desuperheated bypass mixture into a 90° ell inserted against the flow of suction gas to the compres-sor.

Arranging a bypass directly into a suction accumula-tor is often a convenient way to get proper desuperheat-ing of suction gas.

Introducing the hot gas and liquid into the suction line with separate connections is not recommended.

NOTE: Excessive suction gas superheat can cause serious damage to the compressor. As a safety precau-tion, the bypass line solenoid valve should be wired in series with a discharge line thermostat.

Special Applications

On systems where evaporator pressure regulators are used, better control can be reached by installing the bypass regulator equalizer line on the downstream (outlet) side of the EPR so it responds to compressor suction pressure, not evaporator pressure. This results in nearly constant evaporator load balance. See figure 8.

Figure

37

Regulators

Application Tips

• In systems that use a Venturi type distributor, the bypass gas should be fed into the system between the outlet of the expansion valve and the inlet to the distributor. For pressure drop distributors that use an orifice, the inlet must be between the orifice and the inlet to the distributor.

• The hot gas bypass line should be insulated to mini-mize system heat loss.

• In systems with sequential compressor unloading, the valve should be set to start opening at two to three pounds below the last stage of unloading, because compressor unloading is considerably more efficient and should be used before resorting to bypassing.

• For oil return considerations, the bypass line must feed in ahead of the evaporator when the evaporator is installed below the compressor.

• The hot gas bypass valve should be installed as close as practical to the condensing unit, to reduce con-densing ahead of it.

• In systems that operate on a pump down cycle, there must be a solenoid valve or some other means of shutoff in the bypass line.

Adjusting the Set Point

The suction pressure at which the valve opens is selectable by increasing or decreasing the load on the spring by turning an adjusting screw. To set it, the evap-orator must be cooled down by shutting off the fans, blocking off the airflow, or some other means, until the suction pressure drops to at least five pounds below the desired set point. Then, by allowing the pressure to be raised by the bypass gas, the spring load can be varied until the valve closes at precisely the desired set point.

The pressure is set to maintain an evaporator tem-perature just above that at which frost forms.

382008

Oil Controls

39

Oil Controls

OMB

Common Suction

ToCondenser

Filter-Drier CompressorDischarge

OMB OMB OMBOil SeparatorReservoir

Oil Controls

Any time that compressors are operated in a paral-lel operation (Suction and Discharge lines manifolded together), an oil control system in needed to ensure that each compressor has enough oil to operate properly.

Oil control systems are sometimes as basic as a common line connected between compressors to allow oil and gas equalization. This is usually referred to as a “passive” oil system. Although this may suffice on two-compressor systems, compressor racks of three or more compressors almost always have an “active” system since even small differences in crankcase pressures can cause oil starving. This system uses an oil separator to capture most of the oil from the compressor discharge gas since some oil is carried out of the compressor with the refrigerant. Several types of oil separators are commonly used in these applications. The older style is called an impingement type while newer, more efficient types are the centrifugal and coalescing types.

After the oil is separated from the refrigerant, it col-lects in the bottom of the oil separator where it is fed directly to the crankcase in a high-pressure oil system using oil controls on the compressor crankcases.

OMB

Low-Pressure Oil System

High-Pressure Oil System

A low-pressure oil system incorporates a separate oil reservoir which is downstream of the separator. Oil separators in low-pressure oil systems have a float valve in the bottom to allow excess oil to pass to the reservoir whenever the level is high enough in the separator to open the valve. The pressure in the oil reservoir is usually held 20-30 psi above the crank-case pressure through a differential check valve. This lower pressure allows mechanical oil floats, which use a float valve which opens when the crankcase oil level falls below 1/sight glass, to be used to feed oil into the compressor crankcases. The mechanical floats cannot be used on high-pressure oil systems because the oil pressure entering them would be too high and cause them to not be able to control the oil level.

On all oil systems, it is important to install an oil filter downstream of the oil separator to ensure a supply of clean oil to the compressors.

Emerson Oil Controls

A high-pressure oil system can use an Emerson OMB oil control mounted on the compressor crankcase. The OMB is a device which uses a reverse Hall-effect mag-netic float to activate a solenoid to allow oil to flow into the crankcase whenever the level falls below 1/2sight glass level. It is designed to operate at oil pressures up to 350 psid.

OMBOMB

Common Suction

ToCondenser

OilSeparator

Filter-Drier

Reservoir

DifferentialPressure Valve

OMB

CompressorDischarge

402008

TemperaturePressure Controls

41

Temperature-Pressure Controls

Temperature Pressure Controls

Temperature pressure controls serve a number of purposes in refrigeration systems, including the control of compressor cycling, pump-down, defrost control, pressure limiting, loss of charge freeze protection and fan speed control.

TS1 Introduction

The TS1 Series is Emerson’s adjustable thermostats for application in refrigeration and heat pump systems. In these systems, thermostats provide space tempera-ture control, high/low temperature alarming or defrost termination. By operating an electrical contact, a tem-perature value is kept inside a certain limit.

Housing Variants

TS controls are top operated. Top operated controls have adjustment spindles at the top and a display scale, showing temperature setpoint and dif-ferential, at the front. A knob which may be permanently plugged onto one of the adjustment spindles comes with every control. Frost monitors and room thermostats are derivatives of top operated thermostats. They differ by their sensors and other features to suit their target applications.

TS1 Top Operated

Vapor Charge – Sensor Type A, E, PThese sensing elements always sense from the cold-

est point on the capillary, coil, bulb or power element head. For proper operation, the coldest point must be at the part of the sensor which is exposed to the medium temperature to be sensed. The sensing location should be at least 4 degrees F colder than the other parts of the thermal system.

To avoid unwanted effects of heat transfer, for exam-ple from a cold wall, vapor charged thermostats come with an integrated bellows heater (not for frost monitors), which is rated for 230V applications. For other applica-tions, the heater must be disabled or a bellows heater with a different rating should be used.

Besides the bellows heater, room thermostats are supplied with an insulation console for the same reason.

Sensor type ‘A’ is a coiled bulb sensor with two meter capillary, which may be used with or without a bulb well. Style ‘E’ is a coil sensor for space temperature sensing, and type ‘P’ is a capillary type of sensor which can be wrapped around a heat exchanger’s surface to sense the coldest point on the heat exchanger for frost protec-tion applications.

Vapor charges respond faster to temperature chang-es than adsorption and liquid charges.

Vapour Charge

Adsorption Charge

Liquid Charge

-148°F -58 32 122 212 302 392°F

tion are capillary type of sensors, which do not have a bulb, instead, their capillary serves as the bulb directly.

Charges and sensor types are matched to tempera-ture ranges and other application specific characteris-tics. TS1 thermostats come with one of three charge types: vapor charges, adsorption charges or liquid charges. The application temperature range covered by each charge type is shown below:

Temperature Sensing

TS thermostats sense temperature by a thermal system, consisting of temperature charge, bulb, capillary and bellows. The temperature charge changes its pres-sure based on the refrigerant temperature to be sensed. The sensor is the part of the system which is in thermal contact with the refrigerant. The capillary connects the sensor with the bellows and the bellows contracts or expands depending on the temperature, causing the thermostat to operate the electrical contacts. An excep-

42


+-

2 4

1

+-

2 4

1

Adsorption Charge – Sensor Type FAdsorption charged sensor types operate on a tem-

perature dependent adsorption material, which is inside the bulb only. These sensor types always respond to temperature changes at the bulb only. This makes them suitable to applications where it is not always defined which part of the thermal system the coldest point is (cross ambient applications). An example for such ap-plications is defrost control. Adsorption charges are slower in response to tempera-ture changes than vapor charges.

Liquid Charge – Sensor Type CLiquid charge sensors of type ‘C’ always sense from

the warmest point of the thermal system. The sensing location must always be 4 degrees F warmer than other parts of the thermal system.

Setpoints

TS1 are adjustable controls with adjustment spindles for range and differential. Note that manual reset con-trols and some other controls have a fixed differential and no differential spindle. By turning the range spindle, the upper setpoint is defined and by adjusting the dif-ferential spindle, the differential and the lower setpoint is defined.

The dependency between upper and lower setpoint is always as follows:

lower setpoint = upper setpoint – differentialThe following two rules should be kept in mind: an adjustment of the range spindle always affects both upper and lower setpoint. an adjustment of the differential spindle affects the lower setpoint only.

The controls are equipped with display scale and pointers to show the approximate settings.

Top operated controls have display scales in units °C and °F, front operated controls have a display scale in units °C.

For precise setting of the controls, external thermom-eters must be used.

Electrical Contacts

TS1 temperature controls are equipped with high rated double snap action contacts for shatter-free and reliable operation.

All contacts in these controls are designed as Single Pole Double Throw (SPDT) contacts. One contact may be used for control and the other contact for alarm/sta-tus indication or auxiliary control.

Gold plated contacts are available on request for low

electrical loads, for example in electronic signaling ap-plications.

For applications using a supply voltage other than 230V and for applications using gold plated contacts, the bellows heater of vapor charged thermostats (sensor style A, E or P – not for frost monitors function C or D) must be disabled.

Contact Function

Thermostat contacts TS1 are labeled 1-2-4 where ‘1’ refers to the common pole, ‘2’ refers to the lower set-point and ‘4’ refers to the upper setpoint.

The contact function for automatic and manual reset versions is as described below.

Automatic ResetOn temperature rise above the upper setpoint,

contacts 1-open and contacts 4 close. On decreasing temperature lower setpoint contacts 4 open and con-tacts close.

Automatic reset contact function

Manual Reset Low TemperatureOn decreasing temperature below the lower setpoint,

contacts 1-4 open, contacts close and latch. Only on temperature rise above upper setpoint and after press-ing the manual reset button contacts will open and contacts 4 will close again.

Manual reset low temperature contact function

Manual Reset High TemperatureOn increasing temperature above the upper setpoint,

contacts 1-open, contacts 4 close and latch. Only on falling temperature below lower setpoint and after press-ing the manual reset button, contacts 4 will open and contacts 1-will close again.

Manual reset high temperature contact function

+-

2 4

1

43


For operational safety, all TS1 with manual reset are designed as trip-free controls, i.e. pressing the manual reset button while the temperature has not reached its reset threshold will not operate the electrical contacts.

Bellows HeaterTS1 with vapor charges, i.e. sensor types A, E, P

(not frost monitors function C or D) have a bellows heater wired across the contacts in the following way.

Bellows heater

PS1/PS2 Introduction

The PS1/PS2 Series is Emerson’s adjustable pres-sostats for application in refrigeration and heat pump systems.

In these systems, pressure controls serve control and protection functions. Examples of control are compressor cycling, pump-down or defrost control. Protection includes pressure limiting and cut out against excessive pressures, against loss of charge or for freeze protection.

Pressure Sensing

All pressures mentioned in this document are un-derstood as gauge pressures. PS1/PS2 controls sense pressure by bellows which expand or contract when exposed to medium pressure.

High pressure limiters and pressure cut outs with type approval according to EN 12263 feature a double bellows design. The inner bellows serves as the operat-ing bellows and is enclosed by the outer bellows featur-ing a larger surface area.

Single Pressostat PS1

Dual Pressostat PS2

Should the inner bellows leak, then the larger sur-face area of the outer bellows creates a larger force and causes the pressostat to a pre-empted cut out. This represents a fail-safe function. Standard controls for refrigeration applications are equipped with a bronze bellows and can be used with all common HFC, HCFC and CFC refrigerants.

Pressure Connectors

A variety of pressure connectors, including male and female flare type connectors, capillary and solder connectors are available. The standard connector is a 7-16”-20 UNF male flare connector, which, in its high pressure versions, is equipped with a snubber to protect against pressure pulsations.

Electrical Contacts

PS1/PS2 pressure controls are equipped with high rated double snap action contacts for shatter-free and reliable operation.

All contacts in these controls are designed as Single Pole Double Throw (SPDT) contacts. One contact may be used for control and the other contact for alarm/sta-tus indication or auxiliary control. Dual Pressostats PS2 come with two independently actuated SPDT contacts, providing for even further application flexibility by allow-ing for a variety of wiring options.

Ω

2

41

+-

44


Setpoints

PS1/PS2 are adjustable controls with external ad-justment spindles for range and differential. Note that manual reset controls have a fixed differential and no differential spindle. By turning the range spindle, the upper setpoint is defined and by adjusting the differential spindle, the differential and the lower setpoint is defined.

The dependency between upper and lower setpoint is always as follows:

lower setpoint = upper setpoint – differential

The following two rules should be kept in mind: an adjustment of the range spindle always affects both upper and lower setpoint. an adjustment of the differential spindle affects the lower setpoint, only.The controls are equipped with display scale and point-ers to show the approximate settings. The display scales are printed in relative pressure units “bar” and “psi”. For precise setting of the controls, external gauges must be used.

Contact Function

Contacts on Dingle Pressostats, PS1 are labeled 1-2-4 where ‘1’ refers to the common pole, ‘2’ refers to the lower setpoint and ‘4’ refers to the upper setpoint. This is true for all types of controls, irrespective whether they are low pressure controls, high pressure controls, manual or automatic reset types.

The contact function for automatic and manual reset versions is as described below.

Automatic ResetWhen pressure rises above the upper setpoint,

contacts 1-2 open and contacts 1-4 close. On decreas-ing temperature lower setpoint contacts 1-4 open and contacts - close.

Automatic reset contact function

Manual Reset Low PressureWhen pressure drops below the lower setpoint,

contacts 1-4 open, contacts 1-2 close and latch. Only on pressure rise above upper setpoint and after press-ing the manual reset button contacts 1-2 will open and contacts 1-4 will close again.

Manual reset low pressure contact function

Manual Reset High PressureWhen pressure rises above the upper setpoint,

contacts 1-2 open, contacts 1-4 close and latch. Only on falling pressure below lower setpoint and after press-ing the manual reset button, contacts 1-4 will open and contacts 1-2 will close again.

Manual reset high pressure contact function

For operational safety, all PS1/PS2 with manual reset are designed as trip-free controls, i.e. pressing the manual reset button while the pressure has not reached its reset threshold will not operate the electrical contacts.

As Dual Pressostats PS2 have two sets of contacts, their function is the same as on Single Pressostats PS1 with the only difference that the contact labels are pre-ceded by an additional index. One side of the control is labeled 11-12-14 and the second side is 21-22-24.

The contact function of controls with convertible reset is as described above but depends on the position of the convertible reset toggle, i.e. automatic or manual reset position.

+-

2 4

1

+-

2 4

1

+-

2 4

1

P

P

P

45


PSC Pressure Switch

The Flow PSC is a Pressure Switch with fixed switch-point settings.

Features• Maximum Operating Pressure up to 623 psig Test

Pressure up to 696 psig• Standard factory settings from stock in small volumes• High and low pressure switches• High temperature version with snubber for direct com-

pressor mounting (Range 6)• Direct mounting reduces the number of joints and thus

avoiding potential leakage• Precise setting and repeatability• IP 65 protection if used with the cables with plug

Options• For direct mounting on a pressure connection (free standing) or with a capillary tube• Direct compressor head mounting with high temperature bellows and snubber - reduces the number of joints - avoids potential leakage - saves high cost of flexible hose• TÜV approved versions for high and low pressure• Micro-switch for narrow pressure differentials• Gold plated contacts for low voltage/current applications• Cables with plug ordered separately

PSC Introduction

PSC is equipped with a SPDT snap action contact, switching from 1-2 to 1-4 on rising pressure and from 4 to on falling pressure (see diagram). Several models are available:

• Low pressure switch, with automatic or manual reset• High pressure switch, with automatic or manual reset• DIN/TÜV approved safety high pressure limiter with

automatic reset• DIN/TÜV approved safety high pressure cut-out, with

internal or external manual reset

TÜV approval for pressure switches can be reached either by using a double diaphragm (Pressure range 1-5) which acts in a fail-safe mode or by a single pres-sure element (Bellows, Pressure range 6) which is able to resist to >Mio. cycles between 50% and 100% of the maximum operating pressure (see 4.6.1 of EN 12263).

PSC

1

P

2

4

+

-

Bellows (Pressure Range 6)

Single Diaphragm

46


FSX Introduction

FSX electronic speed controllers are designed to control the speed of fan motors in commercial refrigera-tion system depending on condensing pressure chang-es. It is suitable for single phase. FSX can be used in air-cooled condensers, air-cooled condensing units and air-conditioning units.

Using variable fan speed controllers offers the following benefits in commercial refrigeration or air- conditioning applications:• Head pressure can be kept high enough to ensure proper operation of the expansion valve, and sufficient mass flow through the expansion valve to feed the evaporator. This maintains the required cooling capacity.• Efficiency increase of the compressor by controlling the head pressure, improved performance and energy saving for the complete system.• The noise fan motors can be kept at a minimum by avoiding permanent on/off cycling.

Figure 1 – FSX Output Voltage Versus Input Pressure

SupplyVoltage230 V

OutputVoltage99% Maximum range

Minimumrange50%

Cut-off0%

Proportional range

Pressure (bar)Proportional range:FSX-41_: 2,5 barFSX-42_: 3,8 barFSX-43_: 4,6 bar

FSX-43S

Description of control behavior

FSX control behavior can be easily described by looking at the function of output voltage versus input pressure (see figure 1) and by dividing it into maximum, proportional and minimum range.

In the maximum range, the FSX provides a constant output voltage of about 1% below the supply voltage. The fan runs at maximum speed.

Along the proportional range the output voltage var-ies between maximum and minimum voltage of approxi-mately 50% of the supply voltage. This causes the fan speed to slow down from maximum speed to minimum speed.

Further decrease of pressure in the minimum range leads to cut-off of the fan motor. Increase of input pres-sure will start the motor with a hysteresis of approxi-mately 10 psig to avoid cycling (Fig. 1).

The pressure from which motor is cut off (FSX), see column “pressure range” in the selection chart. The pro-portional range is fixed at:

36 psig for FSX-41_/FSM-41_ 55 psig for FSX-42_/FSM-42_ 66 psig for FSX-43_/FSM-43_

472008

Basic Rules ofGood Practice

48

Basic Rules of Good Practice

DOs DO maintain test instruments in good working order and periodically check them against accurately calibrated instruments .

Good diagnoses can’t be made with faulty inputs.

DO familiarize yourself with the operation of a control before attempting to make adjustments or repairs .

If you don’t understand how a control is supposed to function, you can’t be sure if it’s defective or not. When you know what you’re doing, you achieve good results on purpose; when you don’t know what you’re doing, you achieve good results only by accident.

DO make it a practice to check suction gas superheat at the compressor .

Too low superheat may result in liquid flood-back, while high superheats cause high discharge temperatures. Always follow equipment manufacturers’ instructions.

DO replace filter-driers or replaceable cartridges whenever it’s necessary to open a system for service .

Regardless of how careful you are, it’s virtually impossible to prevent the entry of moisture and other contaminants while the system is open. Driers or cartridges cannot be successfully activated in the field for reuse. A new filter drier or cartridge is cheap insurance for a compressor.

DO use an accurate moisture indicator in the liquid line to watch out for moisture contamination .

It is the single most common contaminant, and it can lead to a variety of problems including acid, sludge, and freeze-ups.

DO check expansion valve superheat by using the temperature-pressure method .

This involves measuring the suction line pressure at the evaporator outlet and then referring to the appropriate temperature-pressure chart to determine the satura-tion temperature. Subtracting this temperature from the suction line temperature measured at the remote bulb gives you the operating superheat, which should be adjusted to the equipment manufacturer’s specifications.


Doing a good job in any line of work almost always involves following some basic “good practice” rules, and ser-vicing refrigeration systems is no exception. Knowing and observing such basic rules, to the point that it becomes automatic, can prevent a lot of problems by cutting them off at the pass before they have a chance to happen.

A list of DO’s, procedures that should be followed, and a list of DON’Ts representing pitfalls that should be avoided are presented here to promote the general adoption of good servicing practices and a better understand-ing of the WHYs behind them. An occasional quick review may serve to reinforce awareness and help make their application second nature.

49


DON’Ts DON’T be a “parts-changer .”

Analyze problems based on the symptoms, and determine the specific cause be-fore making any changes or repairs. Emerson’s Troubleshooting Guide describes a wide variety of problems that may be encountered, and their probable causes.

DON’T think of a TXV as a temperature or pressure control .

Thinking of it as a superheat control is basic to achieving optimum system perfor-mance.

DON’T attempt to use any control for any application other than the one it was designed for .

Using a pressure regulator for a pressure relief valve, or any similar substitution, is not good practice and almost certainly won’t deliver proper performance. Mis-applications can lead to equipment damage and even injury. When doubt exists, check with the manufacturer.

DON’T energize a solenoid coil while it is removed from the valve .

Without the magnetic effect of the solenoid core, the coil will burn out in a matter of seconds.

DON’T install a previously used filter-drier or replaceable cartridge.

It could introduce contaminants that it has picked up since its removal from a system.

DON’T select solenoid valves by line size or port size, but by valve capacity .

They must also be compatible with the intended application with regard to the specific refrigerant used, the maximum opening pressure differential (MOPD), the maximum working pressure (MWP), and the electrical characteristics. Never ap-ply a valve outside of its design limits or for uses not specifically catalogued.

DON’T rely on sight or touch for temperature measurements .

Use an accurate thermometer. Once again, you can’t get accurate diagnoses with faulty inputs.

502008

TroubleshootingGuide

51

SystemProblem

DischargePressure

SuctionPressure

Superheat Subcooling Amps

Overcharge

Undercharge

LiquidRestriction

(Drier)

LowEvaporator

Airflow

DirtyCondenser

Low OutsideAmbient

Temperature

InefficientCompressor

TXV BulbLoose

Mounted

TXV BulbLost

Charge

PoorlyInsulated

Bulb

SYSTEM TROUBLESHOOTING GUIDE

52

Superheat Is Too Low -- TXV Feeds Too MuchProblem Symptoms Causes Corrective Action

Valve FeedsToo Much

1) Liquid Slugging

2) Low Superheat

3) Suction Pressure Normal or High

Oversized Valve Replace with correct size valve

Incorrect Superheat Setting Adjust the superheat to correct setting

Moisture Replace the filter-driers; evacuate the systemand replace the refrigerant

Dirt or Foreign Material Clean out the material or replace the valveIncorrect Charge Selection Select proper charge based on refrigerant typeIncorrect Bulb Location Relocate the bulb to proper locationIncorrect Equalizer Location Relocate the equalizer to proper locationPlugged Equalizer (Balanced Port Valve) Remove any restriction in the equalizer tube

Superheat Is Too High -- TXV Doesn't Feed or Doesn't Feed EnoughProblem Symptoms Causes Corrective Action

ValveDoesn'tFeed orDoesn'tFeed

Enough

1) Evaporator Temperature Too High2) High Superheat3) Low Suction Pressure

Short of Refrigerant Add correct amount of refrigerant

High Superheat Change superheat setting

Flash Gas In Liquid Line Remove source of restriction

Low or Lost Bulb Charge Replace power element or valve

Moisture Replace driers or evacuate the system andreplace refrigerant

Plugged Equalizer (Conventional Valve) Remove restriction in equalizer tube

Insufficient Pressure Drop or Valve TooSmall Replace existing valve with properly sized valve

Dirt or Foreign Material Clean out material or replace valve

Incorrect Charge Selection Select correct charge

Incorrect Bulb Location Move bulb to correct location

Incorrect Equalizer Location Move equalizer to correct location

Charge Migration (MOP Only, VaporCharges)

Move valve to a warmer location or apply heattape to powerhead

Wax Use charcoal drier

Wrong equalizer Type Valve Use externally equalized valve

Rod Leakage (Balanced Port Valve) Replace valve

Heat Damaged Powerhead Replace powerhead or valve

No Superheat At Start Up OnlyProblem Symptoms Causes Corrective Action

Valve FeedsToo Much At

Start Up

1) Liquid Slugging2) Zero Superheat3) Suction Pressure Too High

Refrigerant Drainage Use pump down control; Install trap at the topof the evaporator

Compressor or Suction Line in a ColdLocation Install crankcase heater; Install suction solenoid

Partially Restricted or Plugged ExternalEqualizer (Balanced Port Valve) Remove restriction

Liquid Line Solenoid Won't Shut Replace powerhead or valve

Superheat Is Erratic Or HuntsProblem Symptoms Causes Corrective Action

SystemHunts orCycles

1) Suction Pressure Hunts2) Superheat Hunts3) Erratic Valve Feeding

Bulb Location Incorrect Reposition BulbValve Too Large Replace with correctly sized valveIncorrect Superheat Setting Adjust superheat to correct settingSystem Design Redesign system

TROublESHOOTInGExpAnSIOnVAlVES

53

TROublESHOOTInGSOlEnOIdVAlVESProblem Causes Corrective Action

Normally Closed Valve Will Not Open-or-

Normally Open Valve Will Not Close

Movement of plunger or diaphragm restricteda) Corroded partsb) Foreign material lodged in valvec) Dented or bent enclosing tubed) Warped or distorted body due to improperbrazing or crushing in vice

Clean affected parts and replace parts asrequired. Correct the cause of corrosion or sourceof foreign materials in the system.

Improper wiringCheck electrical circuit for loose or brokenconnections. Attach voltmeter to coil leads andcheck voltage, inrush and holding currents

Faulty contacts on relays or thermostats Check contacts in relays and thermostats. clean orreplace as required.

Voltage and frequency rating or solenoid coil notmatched to electrical supply:a) low voltageb) high voltagec) incorrect frequency

Check voltage and frequency stamped on coilassembly to make certain it matches electricalsource. If it does not, obtain new coil assemblywith proper voltage and frequency rating:a) Locate cause of voltage drop and correct.Install proper transformer, wire size as needed. Besure all connections are tight and that relaysfunction properly.b) Excessively high voltage will cause coil burnout.Obtain new coil assembly with proper voltagerating.c) Obtain new coil assembly with proper frequencyrating.

Oversized Valve Install correct sized valve. Consult extendedcapacities tables.

Valve improperly assembled. Assemble parts in proper position making certainnone are missing from valve assembly.

Coil Burnouta) Supply voltage at coil too low (below 85% ofrated coil voltage)b) Supply voltage at valve too high (more than10% above coil voltage rating)c) Valve located at high ambient

d) Plunger restricted due to: corroded parts,foreign materials lodged in valve, dented or bentenclosing tube or warped or distorted body due toimproper brazing or curshing in visee) With valve closed, pressure difference acrossvalve is too high preventing valve from openingf) Improper wiring. Inrush voltage drop causingplunger to fail to pull magnetic field due to:- Wiring the valve to the load side of the motorstarter- Wiring the valve in parallel with anotherappliance with high inrush current draw- Poor connetions, especially on low voltage,where connections should be soldered- Wire size of electrical supply too smallg) Electrical supply (voltage and frequency) notmatched to solenoid coil rating

a) Locate cause of low voltage and correct (checktransformer, wire size, and control rating)b) Locate cause of high voltage and correct(install proper transformer or service)c) Ventilate the area from high ambient. Removecovering from coil housingd) Clean affected parts and replace as required.Connect cause of corrosion or source of foreignmaterial in the system

e) Reduce pressure differential to less than300psif) Correct wiring according to valve manufacturers'instructions. Solder all low voltage connections.Use correct wire size.

g) Check coil voltage and frequency to ensure match to electrical service rating. Install new coil with proper voltage and frequency rating.

Superheat Appears Normal -- System Performs Poorly

Problem Symptoms Causes Corrective Action

Valve Doesn't Feed Properly1) Poor System Performance2) Low or Normal Superheat3) Low Suction Pressure

Unequal Circuit Loading Make modification to balance load

Flow From One Coil AffectingAnother Coil Correct piping

Low Load Correct conditions causing low load

Mismatched Coil/Compressor Correct match

Incorrect Distributor Install correct distributor

Evaporator Oil-Logged Increase gas velocity through coil

54

Symptoms Causes Corrective Action

Doesn't Flow Valve Isn't Open Turn Stem

Leak at Access Schrader Valve Schrader Valve Isn't Tight Tighten Schrader Valve

Leak at Stem Valve Stem is Leaking Replace Valve

Excessive Pressure Drop Valve Isn't Fully Open Turn Stem to Open Valve

TROublESHOOTInGbAllVAlVES

Special Considerations For Industrial Solenoid Valves

Symptoms Causes Corrective Action

High Internal Seat Leakage (high temperaturesteam up to 400°) Wrong Seat Elastomer Used (Buna N) Use Valve with Teflon Seat Elastomer

External Leakage (high temperature steam up to400°) Wrong Gasket Material Used (Neoprene) Use Ethylene Propylene Gasket

High Internal Seat Leakage (high temperaturesteam up to 250° or water up to 210°) Wrong Seat Elastomer Used (Buna N) Use Valve with Ethylene Propylene Seat

ElastomerExternal leakage (high temperature steam up to250° or water up to 210°) Wrong Gasket Material Used (Neoprene) Use Ethylene Propylene Gasket

Suction Line Accumulators

Problem Causes Corrective Action

Oil Not Returning to Compressor

Bleed Hole in U-Tube Plugged Replace Accumulator; Install Filter Ahead ofAccumulator

U-Tube Broken Off Replace Accumulator

Accumulator Too Large for Application Replace with Smaller Accumulator

Accumulator Installed Incorrectly Re-Install with Correct Inlet & Outlet Connections

TROublESHOOTInGSTORAGEdEVICES


Normally Closed Valve Will Not Close-or-

Normally Open Valve Will Not Open

Diaphragm or plunger restricted due to: corrodedparts, foreign material lodged in valve, dented orbent closing tube, or warped body due toimproper brazing or crushing in vise

Clean affected parts and replace parts asrequired. Correct the cause of corrosion or sourceof foreign materials in the system. Install a filter-drier upstream of solenoid valve

Manual opening stem holding valve open With coil de-energized, turn manual stem incounter clockwise direction until valve closes

Closing spring missing or inoperative Re-assemble with spring in proper position

Electrical feedback keeping coil energized, orswitch contacts not breaking circuit to coil

Attach voltmeter at coil leads and check forfeedack or closed circuit. Correct faulty contactsor wiring

Reverse pressures (outlet pressure greater thaninlet pressure), or valve installed backwards

Install check valve at valve outlet, or install withflow arrow in proper direction


Valve Closes, But Flow Continues (Seat Leakage)

Foreign material lodged under seat Clean internal parts and remove foreign material

Valve seat damaged Replace valve or affected parts

Synthetic seat materials chipped Replace valve or affected parts

Valve improperly applied or assembled Replace valve with proper valve or re-assemble

Allowable Pressure Drop -- Permanent Installation

RefrigerantEvaporator Temperature

40°F 20°F 0°F -20°F -40°F

R12, R134a 2.0 1.5 1.0 0.5 -

R22, R410A 3.0 2.0 1.5 1.0 0.5

R502, R404A/507 3.0 2.0 1.5 1.0 0.5

TROublESHOOTInGSySTEMpROTECTORS

55

TROublESHOOTInGOIlCOnTROlS-OMb

Liquid Refrigerant Receivers


Flashing In Liquid Sight Glass Downstream OfReceiver

Receiver Outlet Not Fully Open Open Valve Fully

On Receivers with Top Outlet Connections, theDip Tube may be Broken Off Or Plugged Replace Receiver

Receiver Installed Upside Down Re-Install Receiver Correctly

TROublESHOOTInGOIlSEpARATORSProblem Causes Corrective Action

Reduced or No Oil Feed to Compressor

Oil outlet valve closed or partially closed Open oil outlet valve

Inadequate oil charge in system Add oil in system

Oil float defective or dirty (will not open)Disassemble and clean or replace defective floatcomponent (flanged versions); Replace oilseparator (welded version).

Separator too small for application Replace separator with larger size

Hot Gas Entering Compressor Oil float defective or dirty (will not close)Disassemble and clean or replace defective floatcomponent (flanged versions); Replace oilseparator (welded version).


Oil Level Too High In Sight Glass

OMB out of calibration Replace OMB

Too much oil in system Remove oil from oil separator or reservoir untilproper level is maintained

Too much oil coming back from evaporator

Check system piping design for:- Proper velocities- P-traps at the bottom of all suction risers- Piping pitched to compressor- Overlapping or defrosts that are not staggered

Debris under solenoid valve seat Unscrew solenoid valve, clean & replace


Oil Level Too Low In Sight Glass

Oil separator or reservoir empty Add oil to maintain a liquid seal in the bottom ofthe separator or reservoir

Plugged oil line filter Replace filter

Plugged inlet strainer(s) on OMB Remove and clean strainer on all affected OMB

Solenoid coil defective Replace coil

Power loss to OMB Check power to OMB. Green light should be lit.


Foaming In Sight Glass

Liquid refrigerant in oil

Flood back through suction; Increase superheaton expansion valve; Refrigerant condensing in oilseparator - add heater to oil separator and/oradjust system setting to eliminate flood back

If so equipped, liquid injection overfeeding Correct liquid injection overfeed

Excess quantity of oil in crankcase Remove excess oil


Nuisance Oil Alarms

"Filling" light remains on even though level is 1/2above sight glass Replace OMB

Alarm light on all the time Replace OMB

Intermittent oil return from system

Check system piping design for:- Proper veloicties- P-traps at the bottom of all suction risers- Piping pitched to compressor- Overlapping or defrosts that are not staggered

56


Valve Won't Adjust or Is Erratic Dirt under seatWith system running, open the valve adjustmentto open the valve and flush away the contaminant.If this fails, replace valve.

Valve Throttles Constantly On system equipped with Hot Gas Bypas Valves,the bypass valve setting is higher than CPR

Re-adjust bypass and/or CPR valve so that theCPR setting is higher than the discharge bypassvalve

Temperature Pull-Down After Defrost is Too LongTXV with MOP feature used with the CPR To improve pull-down time, replace TXV with

equivalent without MOP feature

Valve setting is too low Re-adjust the CPR to a higher setting - seeadjustment procedure

TROublESHOOTInGCRAnkCASEREGulATORS


Low Suction Pressure - Valve Open Valve undersized Replace valve with correct size

Will Not Bypass - Valve Not Open

1. Solenoid (if present) not energized2. Valve sticking closed3. Not set properly4. Bad pilot

1. Repair (replace solenoid coil)2. Replace3. Recalibrate4. Replace

Suction Pressure Swings Erratically Oversized valve Replace valve with correct size

Bypass Continuously - Suction Pressure High1. Manual stem screwed down2. Valve sticking open3. Bad pilot

1. Back stem out2. Repair/replace valve3. Replace pilot

Setpoint Drifts Bad pilot Replace pilot

TROublESHOOTInGHOTGASREGulATORS

TROublESHOOTInGREGulATORSProblem Causes Corrective Action

Erratic Pressure ControlPilot inlet filter screen obstructed Clean or replace.

Piston bleed hole restrictionDisassemble valve and clean. Replace ifnecessary.

Regulator Will Not Open(EPRBS Version)

Excessive dirt in pilot/solenoid

Piston bleed hole restriction

Coil is damaged or not energized Verify coil is energized. Replace if necessary.

Excessive Pressure Drop Across the Regulator

Piston bleed partially obstructed Disassemble and clean regulator.

Pilot or solenoid leaking internally Replace pilot assembly.

Regulator undersized Refer to extended capacities table. Install correctsized regulator.

Regulator Hunting(Fluctuations in Controlled Pressure)

Piston bleed port obstructedClean or replace.

Pilot inlet filter screen obstructed

Regulator oversized Refer to extended capacities table. Install correctsized regulator.

Regulator and TXV have control interactionTurn off pilot pressure. Ensure regulator is wideopen. Adjust superheat to required setting. Turnpilot pressure back on.

Regulator and cylinder unloaders have controlinteraction

The unloader should be set to control at least 5psig lower than regulator.

Regulator Will Not Provide Pressure Control

Pilot inlet filter screen obstructed Clean or replace.

Pilot inlet pressure is too low Increase pressure to a minimum of 25 psi higherthan the main valve outlet pressure.

Piston jammed due to excessive dirt; Inoperativepilot or broken diaphragm

Locate and remove the stoppage or dirt. Replacepilot. A broken diaphragm can be detected bychecking for leaks around the adjusting stem.

Regulator Will Not Close(EPRBS Version)

Dirt under seat Disassemble and clean.

Excessive piston seal leakage Replace bell piston assembly.

Plugged pilot filter Clean or replace.

Pilot supply turned off or restricted Verify pilot inlet pressure is at least 25 psiggreater than valve outlet.

Excessive dirt in pilot/solenoid Replace pilot assembly.

57


Compressor tripping on Internal ThermalProtector - Fails to Start-Up and Run Long

Enough to Pull Down TemperatureCPR setting too high Re-adjust the CPR to a lower setting - see

adjustment procedure

Valve Fails to OpenCPR setting is too low

Valve defective - bellows leak, pressurizing theupper adjustment assembly Replace valve

Table 3 - Refrigerant lbs. per ft.*

Refrigerant

Condenser Tube Size - O.D. (in inches)** and Ambient Temperature ° F

3/8" 1/2" 5/8"

40° 0° -20° -40° 40° 0° -20° -40° 40° 0° -20° -40°

R134a .051 .054 .055 .057 .095 .099 .102 .105 .150 .157 .164 .167

R22 .051 .054 .055 .056 .094 .099 .102 .104 .150 .159 .163 .167

R404A/R507A .053 .056 .058 .059 .098 .104 .107 .109 .157 .166 .171 .175


Low Head Pressure During Operation

Valve unable to throttle "C" port1. Foreign material wedged between "C" portseat and seat disc2. Power element lost its charge3. Insufficient winter-time system charge

1. Artificially raise head pressure and tap valvebody to dislodge foreign material2. Change valve3. Add refrigerant per Table 3

Wrong charge pressure in valve for refrigerant Change valve

Receiver exposed to low ambient conditions isacting as condenser Insulate the receiver

Hot gas bypass line restricted or shut off Clear obstruction or open valve

System Runs High Head Pressure-or-

Cycles on High Pressure Cut-Out

Compressor not pumping, restriction in liquidline, low side causing very low suction pressure

Change or repair compressor; clear obstructionor other reason for low suction pressure

Condenser fan not running or turning in wrongdirection

Replace or repair fan motor, belts, wiring orcontrols as required

Fan cycling Run condenser fan continuously while system isrunning

Pressure drop through condenser exceedsallowable 20 psi forcing "B" port partially open

Repipe, recircuit, or change condenser asrequired to reduce condenser pressure drop toless than 20 psi

Condenser undersized or air flow restricted orshort circuiting

Increase size of condenser or remove air flowrestriction or short circuit as required

"B" port wedged open due to foreign materialbetween seat and seat disc

Artificially reduce head pressure below valvesetpoint and tap valve body with system runningto dislodge foreign material

"B" port seat damaged due to foreign materialChange valve

Wrong charge pressure in valve for refrigerant

Excessive system charge or air in system Purge or bleed off refrigerant or non-condensables as system requires

Obstruction or valve closed in discharge orcondenser drain line Clear obstruction or open valve

Liquid line solenoid fails to open Check solenoid

TROublESHOOTInGHEAdpRESSuRECOnTROlS

CHARGING THE SYSTEM - THEORETICAL METHODWeighing the Charge (Method has practical limitations)

Add refrigerant until the sight glass is clear and free of bubbles.Determine refrigerant required to fill the condenser, see Table 3 below. Add this additional amount.

* Return bends: 3/8” O.D. - 20 ft; 1/2 O.D. - 25 ft.; 5/8 O.D. - 30 ft. (equivalent length of tubing/return bend)** Wall thickness: 3/8” O.D. - .016”; 1/2 O.D. - .017”; 5/8 O.D. - .018”

58

NOTES

Emerson Climate Technologies Flow Controls DivisionSt. Louis, Missouri 63141(314) 569-4500WEBSITE: www.emersonclimate.com/flowcontrolsE-MAIL: [email protected]

Form No. 2004FC-141 R4 (4/08)Emerson Climate Technologies and the Emerson Climate Technologies logo are service marks and trademarks of Emerson Electric Co. All other trademarks are property of their respective owner. © 2008 Flow Controls Division. Printed in the USA.

Installation, Operation & Application GuideFor more information on our complete range of American-made products – plus wiring diagrams, troubleshooting tips and more, visit us at www.icmcontrols.com

ICM 450Programmable Three Phase Voltage

Monitor with 25-Fault MemoryProtects motors from premature failure

and burnouts

Specification

Phase Unbalance Protection•Voltage Unbalance:2-20%adjustableOver/Under Voltage Protection•Under Voltage:2-25%adjustable•Over Voltage:2-25%adjustablePhase Loss Protection•Phase Loss Condition:Equals25%ofnominalforanygivenphase;system

willshutdownandafaultwillberecordedshouldthisoccurDelay on Break Timer•Control Voltage:18-240VAC•Time Delay:0to10minutesadjustableFault Interrogation Delay•Time Delay:0to15secondsadjustable•Providesadelaybetweenfaultdetectionandsystemshutdown-helpsto

eliminatenuisancetripsorunnecessaryshutdowns

Parameters

Installation of the ICM450 shall be performed by trained technicians only. Adhere to all local and national electric codes. Disconnect all power to the system before making any connections.

Caution

Input•Line Voltage:Universal,190-630VAC•Frequency:50-60Hz•Load Side Monitoring:Optional•Control Voltage:18-240VAC•Frequency:50-60HzOutput•Type:Relay,SPDT•Voltage Range:240VAC@10Amaximum•Frequency:50-60Hz

Control Operating Temperature•Operating Temperature:-40ºFto+167ºF(-40ºCto+75ºC)•Storage Temperature:-40ºFto+185ºF(-40ºCto+80ºC)LCD Operating Temperature•Operating Temperature:-4ºFto+167ºF(-20ºCto+75ºC)

Mechanical•Mounting:Surfacemountusing(2)#8screws•Terminations:Screwterminals•Weight:12ounces(341grams)

Dimensions •61/2”L,41/4”W,13/8”H(16.5cm.L,10.8cm.W,3.5cm.H)

Installation

•Terminals4and6are“dry,”normallyopencontacts

•Terminals4and6areclosedwhenpoweriswithinspecifications

•Terminals4and6openwhenthereisafaultconditionorlossofcontrolsignal

Contactor Voltage (18-240 VAC)

Contactor Coil

Figure 3

13

6 5 4

Incoming 3-phase voltage from load or

“back” side of contactor(optional)

LOAD 1

LOAD 2

LOAD 3

LINE 1

LINE 2

LINE 3

Figure 1

Incoming 3-phase voltage from line or “front” side of contactor

The incoming 3-phase voltage is used to power up the ICM450 as

well (190-600)

1.Using(2)#8screws,mounttheICM450inacool,dry,easilyaccessiblelocationinthecontrolpanel.

2.ConnectvoltageasshowninFigure1(below).Leaveexistinglineandloadsideconnectionsintactonthecontactor.

3.Loadsidemonitoringisoptional(unitmaybeusedtomonitorlinesideonly).WirethecontactorandoptionalcontrolvoltagemonitoringasinFigures2and3(below).

Note: Load/linewiremustberatedfor3-phasevoltagerating,20gaminimum.

4.Uponapplicationofpower,theICM450willbeonlineandwillbegintomonitorthesystem.

Control Voltage(18-240 VAC)

Short pins when using 24 VAC control voltage

Figure 2

* Switchcanbeathermostat,pressureswitch,etc.

13

6 5 4

•Terminals1and3arethecontrolsignalinputterminals•“ControlMode”isturnedONorOFFinsetup•With“ControlMode”setto“ON,”theremustbea

voltagepresentonterminals1and3fortherelayoutputterminals4and6toclose;thisvoltagecanbesuppliedfromathermostat,pressureswitch,etc.

•Whenthevoltageontheseterminalsisre-applied,theunitwillnotre-energizeuntilthedelayonbreak(0-10minutes)timehaselapsed

•Useofterminals1and3isoptional;theywillbeignoredifthe“ControlMode”issetto“OFF”

ICM450 Wiring Diagrams2-Pole Contactor 3-Pole Contactor

LINE3LINE1

LINE2

LOAD1

LOAD2

LOAD3

Control Voltage

L01

L02

L03

L0AD

LI1

LI3LI2

LINE3LINE1

LINE2

LOAD1

LOAD2

LOAD3

Control Voltage

L01

L02

L03

L0AD

LI1LI2

LI3

1. PressthegreenSETUPbuttontoenterSetupmode.SetupLEDwilllight.2. Usethe and arrowstochangeuserparameters.3. ScrollthroughsetupbypressingandreleasingtheSETUPbutton.4. Whenthelastparameterhasbeenset,thephaseaveragewillbe

displayedandtheSetupLEDwillautomaticallyturnOFF.

Setting the Parameters

Button Functions

Press arrows to scroll through and select user parameter

settings in Setup mode. HOLD down for fast edit.

Press to enter Setup mode

and select user parameters.

Hold for voltage display

a b, b c, a c(simultaneously).

Press to read faults. Hold for 5 seconds to clear faults and

reset memory.

* Thermostat, pressure switch, etc. * Thermostat, pressure switch, etc.

ParametersParameter Description Range Default Recommended

LineVoltage

Averagephasetophaselinevoltage

190-600 208 NameplateVoltage

DelayOnBreak

Amountoftimebetweentheloadde-energizingandre-energizing

0-10minutes

.1minute

4minutes**

FaultInter-rogation

Amountoftimebeforetheloadde-energizesduetoanon-criticalfault*

0-15seconds

15seconds

7-8seconds**

%Over/Under

Voltage

Maximum/minimumphasetophaseaveragevoltage,respectively

2-25% 20% 12-15%**

%PhaseUnbalance

Amountofallowablevoltageunbalance

2-20% 20% 4-5%**

ResetMode

AUTOornumberoftimestheloadcanbere-energizedafteraloadsidefaultbeforeamanualresetisnecessary

Note:Whenmonitoringlinesideonly,theresetmodewillalwaysbeAUTO

AUTO,0-10

AUTO AUTO

ControlMode

WithcontrolmodesettoOFF,theloadwillenergizeifno3-phasefaultconditionsexist;withcontrolmodeON,theloadwillenergizeifnofaultconditionsexistandcontrolvoltageispresentatterminals1and3oftheICM450

ONor

OFF

ON Basedonwiring

* Non-criticalfaultsarefaultssuchasHigh/LowVoltageandPhaseUnbalance.Criticalfaults,suchasPhaseLossandPhaseReversal,haveafaultinterrogationofunder2secondsanditisnotuseradjustable.

** Forbestrecommendations,consultmanufacturerofequipment.

Fault Conditions

* Onlyswapphasesduringinitialsetup,notaftertheICM450hasbeeninoperationwithouterrors.

Pressandreleasefaultbuttontoscrollthroughallsavedfaults.Note:Forinitialsetup,pressandholdFAULTfor5secondsto

removeanypreviouslystoredfaults.

Fault Problem Corrective ActionBackPhaseLoss

Notallthreeofthephasesontheloadsidearepresent

1.Re-energizethecontactor.2. Ifthefaultreappearsaftertheloadenergizes: a. TurnallpowerOFF b. Checkallloadsideconnections c. Checkthecontactsofthecontactorfordebris

orexcesscarbon.

BackPhaseRev

Loads1,2,or3arenotinsequence(not120ºphaseshifted)

1.TurnOFFallpower.2.Swapany2phasesontheloadsideofthe

ICM450only(example:swapload1andload2)*3.Re-applypower.

BackPhaseUnbal

Avoltageunbalancebetweenthethreeloadphasesexceedstheunbalancesetpoint

1.PresstheREADbuttontoobservethepresentloadvoltages.Checksystemforunbalancecause.

2. Increasethefaultinterrogationtimeifnecessary.3. Increasethepercentunbalancesettingif

necessary.

FrontOverVolt

Averagephase-phasevoltageexceedsthemaximumpercentage

1.Checksystemforover-voltagecause.2. Increasethepercentover-voltagesettingif

necessary.3. Increasethefaultinterrogationtimeifnecessary.

FrontPhaseLoss

Notallthreeofthephasesonthelinesidearepresent

1.PressandholdtheREADbuttononthephasemonitororuseanACvoltmetertocarefullymeasureallthreephase-phaselinevoltages(example:Line1 Line2,Line2 Line3,Line3 Line1).

2.Repairthemissingphase.

FrontPhaseRev

Lines1,2,or3arenotinsequence(not120ºphaseshifted)

1.TurnOFFallpower.2.Swapany2phasesonthelinesideoftheICM450

(example:swapload1andload2)*3.Re-applypower.

FrontPhaseUnbal

Avoltageunbalancebetweenthethreelinephasesexceedstheunbalancesetpoint

1.PresstheREADbuttontoobservethepresentloadvoltages.Checksystemforunbalancecause.

2. Increasethefaultinterrogationtimeifnecessary.3. Increasethepercentunbalancesettingif

necessary.

FrontUnderVolt

Averagephase-phasevoltageisbelowtheminimumpercentage

1.Checksystemforunder-voltagecause.2. Increasethepercentunder-voltagesettingif

necessary.3. Increasethefaultinterrogationtimeifnecessary.

Troubleshooting

Problem LCD Readout LED Status Corrective Action

Loadwillnotenergize

PhaseAvg.

AllLEDsOff Confirmthatthecontrolinput(terminals1&3)isproperlyconnectedandconfigured(seePages1and3)

Loadwillnotenergize

PhaseAvg.

LoadLEDOff,FaultLEDblinking

PressFAULTtoobservethecurrentfault;correcttheconditionofthefirstfaultthatappears(seeFaultConditions,Page4foralistofcorrectiveactions)

FaultLEDblinks

repeatedlywhileloadisenergized

PhaseAvg.

FaultLEDBlinking,

LoadLEDOn

Indicatestherearefaultssavedinthememory,pressFAULTrapidlytoscrollthroughsavedfaults;toclearthefaults,pressandholdFAULTformorethan5seconds

Loadwillnotde-energize

whencontrolvoltageisOFF

PhaseAvg.

LoadLEDOn,ControlLEDOff

ThecontrolmodesettingisOFF;pressSETUPtogettothecontrolmode.Press tosetthecontrolmodeON

SetupLEDisonwhile

loadisbeingenergized

AnythingOtherThanPhaseAvg.

SetupLEDOn,LoadLEDOn

Toexitthesetupmode,presseitherREADorFAULT

Loadwillnotenergize

Reset FaultLEDBlinking

Unitinlockout;maximumnumberofretriesinmanualresetmodehasbeenreached;toresetunit,pressFAULTandholdformorethan5seconds

LoadturnsONandOFF

repeatedly

ReadoutisIrrelevant

FaultLEDBlinking

Fixloadsidefault;pressFAULTtoobservecondition;thedelayonbreakperiodmaybetooshort;pressSETUPtoenterthedelayonbreakmode;press tolengthenthedelay

ONE-YEAR LIMITED WARRANTYTheSellerwarrantsitsproductsagainstdefectsinmaterialorworkmanshipforaperiodofone(1)yearfromthedateofmanufacture.TheliabilityoftheSellerislimited,atitsoption,torepair,replaceorissueanon-casecreditforthepurchasepricesofthegoodswhichareprovidedtobedefective.ThewarrantyandremediessetforthhereindonotapplytoanygoodsorpartsthereofwhichhavebeensubjectedtomisuseincludinganyuseorapplicationinviolationoftheSeller’sinstructions,neglect,tampering,improperstorage,incorrectinstallationorservicingnotperformedbytheSeller.InordertopermittheSellertoproperlyadministerthewarranty,theBuyershall:1)NotifytheSellerpromptlyofanyclaim,submittingdatecodeinformationoranyotherpertinentdataasrequestedbytheSeller.2)PermittheSellertoinspectandtesttheproductclaimedtobedefective.ItemsclaimedtobedefectiveandaredeterminedbySellertobenon-defectivearesubjecttoa$30.00perhourinspectionfee.ThiswarrantyconstitutestheSeller’ssoleliabilityhereunderandisinlieuofanyotherwarrantyexpressed,impliedorstatutory.Unlessotherwisestatedinwriting,Sellermakesnowarrantythatthegoodsdepictedordescribedhereinarefitforanyparticularpurpose.

LIA164-4

7 William Barry Blvd., North Syracuse, NY (Toll Free) 800-365-5525 (Phone) 315-233-5266 (Fax) 315-233-5276

www.icmcontrols.com

ICM 450Programmable Three Phase Voltage Monitor

Parameters Default settingsLine voltage 208 V See Name Plate

.1 minute 1 minuteFault delay 15 sec 5 sec

20% 5%20% 5%

Phase unbalance 20% 3%Reset Mode AUTO AUTOControl Mode ON OFF

Settings for Seresco NE series dehumidifiersSeresco Settings

Dealay on break

OvervoltageUndervoltage

Note: Please reffer to ICM 450 manual. Consult Seresco if settings' change is required

SPOR

LAN

REF.

& A

/C P

RODU

CTS

Sporlan Refrigeration and Air Conditioning Products

Oil Level Controls

Suction Filters Oil Filters

See•All

Head Pressure Control Valves

Solenoids

Three-Way Heat Reclaim Valves

TEV

Crankcase Pressure Regulating Valves

Catch-All

Discharge Bypass Valves

Evaporator Pressure Regulating Valves

SPORLAN REF. & A/C PRODUCTS

632

THERMOSTATIC EXPANSION VALVES SPORLAN THERMOSTATIC EXPANSION VALVES

• Selective Thermostat Charges — Designed to provide optimum performance for all applications — air conditioning and heat pump, medium and Low temperature refrigeration.

• Thermostatic Element Design — Long lasting and field proven stainless steel diaphragm and welded element construction.

• Diaphragm Design — Large flat diaphragm permits precise valve control.

• Replaceable Thermostatic Elements — Field replaceable elements on all standard valves.

• Balanced Port Design — Provides perfect pin and port alignment, and prevents changes in pressure drop across the valve from influencing Valve operation. Provides excellent control on applications with widely varying operating conditions.

• Pin Carrier Design (Conventional Valves) — Provides precise pin and port alignment, and tighter seating.

• Accessible Internal Parts — Durable, leak proof body joint construction allows the valve to be disassembled, and the internal parts cleaned and inspected.

• Materials of Construction — Pin and port material offer maximum protection against corrosion and erosion.

• Silver Soldered Connections — For leak proof, high strength connection-to-body joints.

• Adjustable Superheat Design — All standard valves are externally adjustable. VALVE NOMENCLATURE/ORDERING INSTRUCTIONS

Combine the letters and numbers in the following manner to obtain the complete valve designation. Also include all connection Sizes and the capillary tube length. CONVENTIONAL VALVES:

S V E - 8 - GA 5/8”ODF Solder X 7/8”ODF

Solder X 1/4” ODF Solder X 5’

Sporlan Code - REFRIGERANT - Element Label Color Code Body

Type: FB,F, EF,G, EG,

RI,RC, S,

EBS*, O*, V**, W**

F - R-12 Yellow E - R-13 - Blue V - R-22 -Green G - R-23 - Blue M - R124 - Blue J- R134a -Blue X - R-401A Pink L - R-402ASand S- R-404A Orange

V - R-407A – Green N - R-407 Lt. Brown S - R-408A -Purple F - R-409A -Yellow R - R-502 - Purple W - R-503 - Blue P - R-507 - Teal W - R-508B - Blue A - R-717 – White

E” specifies external

equalizer. Omission of

letter “E” indicates valve with internal

equalizer. e.g.

EGV-1-C

Nominal Capacityin Tons

ThermostaticCharge

Inlet

Connection

Size and Style

Outlet Connection

Size and Style

External Equalizer

Connection

Size and

Style

CapillaryTubing Length (Inches or Feet)

BALANCE PORTED VALVES:

EBF

V

E

-

AA

-

C 3/8”

Extended ODF Solder

X

1/2” Extended

ODF Solder

X

1/4” Extended

ODF Solder

X

30”

Port Size

Nominal Capacity in Tons

AAA 1/8 thru 1/3 AA 1/2 thru 2/3 A 3/4 thru 1-1/2 B 1-3/4 thru 3

22 (V) 407C (N) 407A (V)

C 3-1/4 thru 5-1/2 AAA 1/8 thru 1/5 AA 1/4 thru 1/3 A 1/2 thru 1 B 1-1/4 thru 1-3/4

134a (J) 12 (F)

401A (X) 409A (F)

C 2 thru 3 AAA 1/8 thru 1/5 AA 1/4 thru 1/3 A 1/2 thru 1 B 1-1/4 thru 2

404A (S) 502 (R)

408A (S)

C 2-1/4 thru 3 AAA 1/8 thru 1/5 AA 1/4 thru 1/3 A 1/2 thru 1 B 1-1/4 thru 2

Body Type:

BF,SBF, EBF

507 (P) 402A (L)

“E” specifies external

equalizer. Omission of

letter “E” indicates

valve with internal equalizer.

C 2-1/4 thru 3

Thermostatic Charge

Inlet Connection

Size and Style

Outlet Connection

Size and

Style

External Equalizer

Connection

Size and Style

Capillary Tubing Length (Inches)

*EBS and O valves are balance ported valves, but follow conventional valve nomenclature. **V and W valves have dual port semi-balance design.

THERMOSTATIC EXPANSION VALVES

633

THER

MOST

ATIC

EXP

ANSI

ON V

ALVE

S SPORLAN SELECTIVE CHARGES ENGINEERED FOR PEAK PERFORMANCE FOR EACH SPECIFICAPPLICATIONRECOMMENDED THERMOSTATIC CHARGES*

REFRIGERANT

APPLICATION

12 409A

22 407A

134a

401A

402A

404A 408A

407C

502

507

717

ACTUAL THERMOSTATIC

CHARGES FCP60 — JCP60 XCP60 — — — — — — FCP60

— VCP100 — — — — NCP100 — — — VCP100 — VGA — — — — NGA — — — VGA

AIR CONDITIONING — — — — — SCP115 — RCP115 — — SCP115

FC — JC XC — — — — — — FC — VC — — — — NC — — — VC — — — — — SC — RC — — SC — — — — LC — — — PC — PC

COMMERCIAL REFRIGERATION 50°F

TO -10°F — — — — — — — — — AC, AL AC, AL

FZ — — — — — — — — — FZ FZP — — — — — — — — — FZP — VZ — — — — — — — — VZ — VZP40 — — — — — — — — VZP40 — — — — LZ SZ — RZ PZ — SZ — — — — LZP SZP — RZP PZP — SZP

LOW TEMPERATURE REFRIGERATION 0°F

TO -40°F — — — — — — — — — AZ, AL AZ, AL

— VX — — — — — — — — VX EXTREME LOW TEMP.REFRIGERATION

-40°F TO -100°F — — — — LX SX — RX PX — SX * APPLICATION FACTORS: 1. The Type ZP charges have essentially the same characteristics as the Type Z charge with one exception: they produce a pressure limit Maximum Operating Pressure (MOP). ZP charges are not intended as replacements for Z charges. Each should be selected for its own unique purpose.

2. All air conditioning and heat pump charges are intended for use with externally equalized valves.

3. Type L liquid charges are also available for most commonly used refrigerants in most element sizes.

4. If in doubt as to which charge to use, contact Sporlan Valve Company, Washington, Missouri with complete system data.

5. The Type X charges are not to be used with “EBS” and “O” valves. IMPORTANT NOTES:

A. R-134a air conditioning and commercial refrigeration applications are using R-12 or R-409A or R-401A valves.

B. R-404A commercial refrigeration applications are using R-502 or R-408A valves.

C. R-404A and R-507 low temperature refrigeration applications are using R-502 or R-402A or R-408A valves.


634

THERMOSTATIC EXPANSION VALVES QUICK REFERENCE GUIDE — REFRIGERATION VALVES

NOMINAL CAPACITY

RANGE (Tons)

VALUE TYPE

R-22

R-134a R-404A

& R-507

CONNECTION TYPES

VALVE DESCRIPTION AND APPLICATION

F

1/5 thru

3

1/8 thru

2

1/8 thru

2

SAE Flare

Small brass bar body, externally adjustable valve for small capacity refrigeration systems. SAE flare inlet

connection has a removable 100 mesh strainer. Typical applications: Refrigerated cases, coolers, freezers.

EF

1/5 thru

3

1/8 thru

2

1/8 thru

2

ODF Solder

Same as the Type F valve except it features ODF solder connections. The inlet connection has a 50 mesh strainer. Typical applications: Refrigerated

cases, coolers, freezers.

G

1/5 thru

3

1/8 thru

2

1/8 thru

2

SAE Flare

Forged brass bar body, externally adjustable valve for small capacity refrigeration systems. Inlet connection

has a removable 100 mesh strainer. Typical applications: Refrigerated cases, coolers, freezers and

small capacity air conditioners.

EG

1/5 thru

3

1/8 thru

2

1/8 thru

2

ODF Solder

Same as the Type G valve except it features ODF solder connections and a forged brass inlet fitting with a removable 100 mesh strainer which can be cleaned

and/or replaced without moving the valve from the line.

FB

1/4 thru

8

1/4 thru

5

1/4 thru

6

SAE Flare

or ODF Solder

Small brass body valve available only with straight through connections and external adjustment. Typical

applications: Small capacity air conditioning and refrigeration applications where an external adjustment

is desired

BF

1/3 thru

5

1/4 thru

3

1/4 thru

3

SAE Flare

Same physical size as the Type F valve with SAE flare connection except it features a balanced port

construction. Inlet connection has removable 100 mesh strainer. Typical applications: Small capacity refrigeration that operates over widely varying operating conditions.

SBF

1/3 thru

5

1/4 thru

3

1/4 thru

3

Extended

ODF Solder

Same as the Type BF valve except it features ODF solder connection and a forged brass inlet fitting with a

removable 100 mesh strainer which can be cleaned and/or replaced without removing the valve from

the line.

EBF

1/3 thru

5

1/4 thru

3

1/4 thru

3

Extended

ODF Solder

Same as the Type BF valve except it features ODF

solder connections.

S

2

thru 10

2

thru 6

2

thru 7

ODF Solder

Brass bar body, externally adjustable valve. General purpose valve for air conditioning and refrigeration

applications.

EMC

0.64 thru 2.34

0.46 thru 1.69

0.42 thru 1.51

ODF Solder

Multi-capacity two part valve designed to perform

effectively over the range of load conditions inherent with most refrigeration systems. Large port is for pull down load and smaller port to control holding loads.


635

THER

MOST

ATIC

EXP

ANSI

ON V

ALVE

S PART NO*

SPORLAN MODEL**

PART NO*

SPORLAN MODEL**

PART NO*

SPORLAN MODEL**

TYPE F

TYPE BF

TYPE FB

FF-1-1/2-C 3X4 SAE 30" BFF-A-C 3X4 SAE 30" FBS-1/4-C 3SX4 ODF 30"

FF-1-C 3X4 SAE 30" BFJE-A-C 3X4 SAE 30" FBS-1/4-Z 2SX4 ODF 30"

FFE-1-C 3X4 SAE 30" BFJE-B-C 3X4 SAE 30" FBS-1/4-ZP 3SX4 ODF 30"

FFE-2-C 3X4 SAE 30" BFR-A-C 3X4 SAE 30" FBSE-1/2-C 3SX4X2 ODF 30"

FJ-1/2-C 2X4 SAE 30" BFRE-A-Z 3X4 SAE 30" FBSE-1/4-C 3SX4X2 ODF 30"

FJ-1/4-C 2X4 SAE 30" BFRE-A-ZP 3X4 SAE 30" FBSE-1/4-ZP 3SX4X2 ODF 30"

FJ-1/4-Z 2X4 SAE 30" BFRE-B-C 3X4 SAE 30" FBSE-1\2-ZP 3SX4 ODF 30"

FR-1/4-Z 2X4 SAE 30" BFRE-B-Z 3X4 SAE 60" FBSE-1-1\2-C 3SX4 ODF 30"

FRE-1/2-C 3X4 SAE 30" BFRE-B-ZP 3X4 SAE 30" FBSE-1-1\2-ZP 3SX4 ODF 30"

FRE-1/2-Z 3X4 SAE 30" BFSE-AA-ZP 3X4 SAE 30" FBSE-1-C 3SX4 ODF 30"

FRE-1/2-ZP 3X4 SAE 30" BFSE-A-C 3X4 SAE 30" FBSE-1-Z 3X4X2 ODF 30"

FRE-1/4-Z 2X4 SAE 30" BFSE-C-ZP 3X4 SAE 30" FBSE-1-ZP 3SX4 ODF 30"

FRE-1-1/2-C 3X4 SAE 30" BFV-AA-C 3X4 SAE 30" FBSE-2-C 3SX4X2 ODF 30"

FRE-1-1/2-Z 3X4 SAE 30" BFV-A-C 3X4 SAE 30" FBSE-2-Z 3X4X2 ODF 30"

FRE-1-1/2-ZP35 2X4 SAE 30" BFVE-AAA-C 3X4 SAE 30" FBSE-2-ZP 3SX4X2 ODF 30"

FRE-1-ZP 3X4 SAE 30" BFVE-AA-C 3X4 SAE 30" FBSE-3.5-C 4X7X2 ODF 60"

FRE-2-Z 3X4 SAE 30" BFVE-A-C 3X4 SAE 30" FBSE-3.5-ZP 4X7X2 ODF 30"

FRE-2-ZP 3X4 SAE 30" BFVE-B-C 3X4 SAE 30" FBSE-3-C 4X7X2 ODF 60"

FS-1/2-C 2X4 SAE 30" FBSE-3-ZP 4X7X2 ODF 30"

FS-1/4-C 2X4 SAE 30" FBSE-4.5-C 4X7X2 ODF 60"

FS-1/4-ZP 2X4 SAE 30" FBSE-4.5-ZP 4X7X2 ODF 30"

FSE-1/2-Z 2X4 SAE 30" FBSE-6-C 5X7X2 ODF 60"

FSE-1/2-ZP35 2X4 SAE 30" FBSE-6-ZP 5X7X2 ODF 30"

FSE-1/4-ZP 2X4 SAE 30" FBV-1/4-C 2*SX4 ODF 30"

FSE-1/4-ZP30 2X4 SAE 30"

TYPE G

FBV-1/4-C 3*SX4 ODF 30"

FSE-1-C 3X4 SAE 30" GRE-1-1/2-ZP 3X4 SAE 5' FBV-1/4-ZP40 3SX4 ODF 30"

FV-1/4-C 2X4 SAE 30" GRE-1-ZP 3X4 SAE 5' FBVE-1/2-ZP40 3*SX4X2 ODF 30"

FVE-1/2-C 3X4 SAE 30" GVE-1-C 3X4 SAE 5' FBVE-1/4-C 3*SX4X2 ODF 30"

FVE-1/4-C 2X4 SAE 30" GVE-3/4-C 3X4 SAE 5' FBVE-1/4-ZP40 3*SX4X2 ODF 30"

FVE-1-1/2-C 3X4 SAE 30" GVE-3/4-ZP 3X4 SAE 5' FBVE-1\2-C 3*SX4 ODF 30"

FVE-1-C 3X4 SAE 30" GVE-3-C 3X4 SAE 5' FBVE-1-1/2-ZP40 3*SX4X2 ODF 30"

FVE-2-C 3X4 SAE 30" FBVE-1-1\2-C 3*SX4 ODF 30"

FVE-3-C 3X4 SAE 30" FBVE-1-C 3*SX4 ODF 30"

FBVE-1-ZP40 3*SX4X2 ODF 30"

FBVE-2.5-C 4X5X2 ODF 60"

FBVE-2.5-ZP40 4X5X2 ODF 30"

TYPE FB FBVE-2-C 4X5X2 ODF 30"

FBFE-1-C 3SX4X2 ODF 30" FBVE-2-ZP40 4X5X2 ODF 30"

TYPE EF

FBJE-1/2-CP60 3X4X2 ODF 30"

FBVE-3-C 4X5X2 ODF 60"

EFF-1/4-Z 2SX3 ODF 30" FBJE-1/2-Z 3X4X2 ODF 30" FBVE-3-ZP40 4X5X2 ODF 60"

EFJ-1/2-C 2SX3 ODF 30" FBR-1/2-Z 2X4 SAE 30" FBVE-4-C 4X7X2 ODF 60"

EFJ-1/4-C 2SX4 ODF 30" FBR-1/4-Z 2X4 SAE 30" FBVE-4-ZP40 4X7X2 ODF 60"

EFS-1/4-C 2SX3 ODF 30" FBS-1/2-C 3SX4 ODF 30" FBVE-5-C 4X7X2 ODF 60"

EFS-1/4-Z 2SX3 ODF 30" FBS-1/2-Z 2SX4 ODF 30" FBVE-5-ZP40 4X7X2 ODF 60"

EFS-1-Z 3X4 ODF 30" FBS-1/2-ZP 3SX4 ODF 30" FBVE-6-C 4X7X2 ODF 60"

EFSE-1/2-Z 3X4 ODF 30" FBVE-6-GA 4X5X2 ODF 30"

EFSE-1/4-Z 3X4 ODF 30" FBVE-6-ZP40 4X7X2 ODF 60"

EFSE-1/6-Z 2X4 ODF 30" FBVE-8-C 5X7X2 ODF 60"

EFVE-1/2-C 3X4 ODF 30" FBVE-8-ZP40 5X7X2 ODF 60"

EFVE-1/2-L1 3X4 ODF 30"

EFVE-1/3-C 2X4 ODF 30"


EFVE-1/3-L1 3X4 ODF 30"


EFVE-1-C 3X4 ODF 30"

IMPORTANT NOTE:

00*S - with Insert Strainer Connection Sizes are in eighths of inch – (3x4 means 3/8” inlet x 1/2” outlet).

*( ) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service Center for part number and pricing.


636

THERMOSTATIC EXPANSION VALVES PART NO*

SPORLAN MODEL** PART NO*

SPORLAN MODEL** PARTNO*


SPORLAN MODEL**

EGV-1/2-ZP40 3X4 ODF 5' SBFP-AAA-Z 3X4 ODF 30"

EGV-1/3-C 3X4 ODF 5' SBFP-AA-C 3X4 ODF 30"

EGV-1/3-Z 3X4 ODF 5' SBFP-AA-Z 3X4 ODF 30"

EGV-1/5-C 3X4 ODF 5' SBFP-A-C 3X4 ODF 30"

EGV-1/5-Z 3X4 ODF 5' SBFP-B-C 3X4 ODF 30"

EGV-1-C 3X4 ODF 5' SBFPE-AAA-C 3X4 ODF 30"

TYPE EG

EGV-3/4-C 3X4 ODF 5'

SBFPE-AA-C 3X4 ODF 30"

TYPE EBF

EGFE-1/2-C 3X4 ODF 5' EGV-3/4-Z 3X4 ODF 5' SBFPE-AA-Z 3X4 ODF 30" EBFF-AAA-C 3X4 ODF 30"

EGFE-1/4-C 3X4 ODF 5' EGV-3/4-ZP 3X4 ODF 5' SBFPE-B-C 3X4 ODF 30" EBFF-A-C 3X4 ODF 30"

EGFE-1-C 3X4 ODF 5' EGV-3/4-ZP40 3X4 ODF 5' SBFPE-C-C 3X4 ODF 30" EBFFE-A-C 3VX4 ODF 30"

EGFE-2-C 3X4 ODF 5' EGVE-1/2-C 3X4 ODF 5' SBFR-AAA-Z 3X4 ODF 30" EBFFE-B-C 3X4 ODF 30"

EGJ-1/4-C 3X4 ODF 5' EGVE-1/2-L1 3X4 ODF 5' SBFR-AAA-ZP 3X4 ODF 30" EBFLE-A-C 3X4 ODF 30"

EGJ-1/6-C 3X4 ODF 5' EGVE-1/2-Z 3X4 ODF 5' SBFR-AA-C 3X4 ODF 30" EBFLE-A-Z 3X4 ODF 30"

EGJ-1/8-C 3X4 ODF 5' EGVE-1/2-ZP40 3X4 ODF 5' SBFR-AA-Z 3X4 ODF 30" EBFPE-C-C 3X4 ODF 30"

EGJE-1/6-C 3X4 ODF 5' EGVE-1/3-C 3X4 ODF 5' SBFR-AA-ZP 3X4 ODF 30" EBFPE-C-Z 3X4 ODF 30"

EGJE-1/8-C 3X4 ODF 5' EGVE-1/5-C 3X4 ODF 5' SBFR-A-C 3X4 ODF 30" EBFR-A-C 3EX4 ODF 30"

EGJE-1-1/2-C 3X4 ODF 5' EGVE-1-1/2-C 3X4 ODF 5' SBFR-A-ZP 3X4 ODF 30" EBFRE-AA-Z 3VX4 ODF 30"

EGP-1/2-C 3X4 ODF 5' EGVE-1-1/2-Z 3X4 ODF 5' SBFR-B-C 3X4 ODF 30" EBFRE-AA-ZP 3VX4 ODF 30"

EGP-1/4-C 3X4 ODF 5' EGVE-1-1/2-ZP40 3X4 ODF 5' SBFRE-AAA-C 3X4 ODF 30" EBFRE-A-Z 3EX4 ODF 30"

EGP-1/6-C 3X4 ODF 5' EGVE-1-C 3X4 ODF 5' SBFRE-AAA-Z 3X4 ODF 30" EBFRE-A-Z 3X4 ODF 30"

EGP-1/8-C 3X4 ODF 5' EGVE-1-Z 3X4 ODF 5' SBFRE-AA-Z 3X4 ODF 30" EBFRE-A-ZP 3EX4 ODF 30"

EGPE-1/2-C 3X4 ODF 5' EGVE-1-ZP40 3X4 ODF 5' SBFRE-A-Z 3X4 ODF 30" EBFS-AAA-ZP 2X4 ODF 30"

EGPE-1/4-C 3X4 ODF 5' EGVE-2-C 3X4 ODF 5' SBFRE-B-Z 3X4 ODF 30" EBFSE-AAA-Z 2SX4 ODF 30"

EGPE-1/8-C 3X4 ODF 5' EGVE-2-Z 3X4 ODF 5' SBFS-AAA-C 3X4 ODF 30" EBFSE-AAA-ZP 3VX4 ODF 30"

EGPE-1-1/2-C 3X4 ODF 5' EGVE-2-ZP40 3X4 ODF 5' SBFSE-AAA-ZP 3X4 ODF 30" EBFSE-AA-C 3X4 ODF 30"

EGPE-1-C 3X4 ODF 5' EGVE-3/4-C 3X4 ODF 5' SBFSE-AA-C 3X4 ODF 30" EBFSE-A-C 3VX4 ODF 30"

EGPE-2-C 3X4 ODF 5' EGVE-3/4-L1 3X4 ODF 5' SBFSE-AA-ZP 3X4 ODF 30" EBFSE-A-Z 3VX4 ODF 30"

EGR-1/2-C 3X4 ODF 5' EGVE-3/4-X 3X4 ODF 5' SBFSE-A-C 3X4 ODF 30" EBFSE-B-C 3VX4 ODF 30"

EGR-1/2-Z 3X4 ODF 5' EGVE-3/4-Z 3X4 ODF 5' SBFSE-A-ZP 3X4 ODF 30" EBFSE-B-Z 3VX4 ODF 30"

EGR-1/2-ZP 3X4 ODF 5' EGVE-3/4-ZP 3X4 ODF 5' SBFSE-B-C 3X4 ODF 30" EBFSE-B-ZP 3X4 ODF 30"

EGR-1/4-C 3X4 ODF 5' EGVE-3/4-ZP40 3X4 ODF 5' SBFSE-B-Z 3X4 ODF 30" EBFSE-C-C 3X4 ODF 30"

EGR-1/4-Z 3X4 ODF 5' EGVE-3-C 3X4 ODF 5' SBFSE-B-ZP 3X4 ODF 30" EBFSE-C-Z 3X4 ODF 30"

EGR-1/6-C 3X4 ODF 5' EGVE-3-Z 3X4 ODF 5' SBFSE-C-C 3X4 ODF 30" EBFSE-C-ZP 3VX4 ODF 30"

EGR-1/8-C 3X4 ODF 5' EGVE-3-ZP40 3X4 ODF 5' SBFSE-C-Z 3X4 ODF 30" EBFV-AAA-C 3EX4 ODF 30"

EGR-1/8-Z 3X4 ODF 5' EGX-1/2-C 3X4 ODF 5' SBFSE-C-ZP 3X4 ODF 30" EBFV-AA-C 3EX4 ODF 30"

EGR-1-C 3X4 ODF 5' SBFV-AAA-C 3X4 ODF 30" EBFV-AA-Z 3EX4 ODF 30"

EGRE-1/4-Z 3X4 ODF 5' SBFV-AAA-Z 3X4 ODF 30" EBFV-AA-ZP40 3EX4 ODF 30"

EGRE-1/6-C 3X4 ODF 5' SBFV-AA-C 3X4 ODF 30" EBFV-A-C 3EX4 ODF 30"

EGRE-1/8-C 3X4 ODF 5' SBFV-AA-Z 3X4 ODF 30" EBFV-B-C 3X4 ODF 30"

EGRE-1-ZP40 3X4 ODF 5' SBFV-AA-ZP40 3X4 ODF 30" EBFVE-AAA-C 3X4 ODF 30"

EGRE-2-C 3X4 ODF 5'

TYPE SBF SBFV-A-C 3X4 ODF 30" EBFVE-AA-C 3EX4 ODF 30"

EGRE-2-Z 3X4 ODF 5' SBFF-AA-ZP 3X4 ODF 30"

SBFV-B-C 3X4 ODF 30"

EBFVE-AA-CP100 3VX4 ODF 30"

EGSE-1/2-C 3X4 ODF 5' SBFF-A-ZP 3X4 ODF 30" SBFVE-AAA-C 3X4 ODF 30" EBFVE-AA-Z 3EX4 ODF 30"

EGSE-1/2-Z 3X4 ODF 5' SBFFE-AA-ZP 3X4 ODF 30" SBFVE-AAA-ZP40 3X4 ODF 30" EBFVE-AA-ZP40 3EX4 ODF 30"

EGSE-1/2-ZP 3X4 ODF 5' SBFFE-A-ZP 3X4 ODF 30" SBFVE-AA-C 3X4 ODF 30" EBFVE-A-C 3EX4 ODF 30"

EGSE-1/4-C 3X4 ODF 5' SBFFE-B-ZP 3X4 ODF 30" SBFVE-AA-Z 3X4 ODF 30" EBFVE-A-Z 3X4 ODF 30"

EGSE-1/4-ZP 3X4 ODF 5' SBFJ-AAA-C 3X4 ODF 30" SBFVE-AA-ZP40 3X4 ODF 30" EBFVE-A-ZP40 3VX4 ODF 30"

EGSE-1-1/2-C 3X4 ODF 5' SBFJ-AA-C 3X4 ODF 30" SBFVE-A-C 3X4 ODF 30" EBFVE-B-C 3X4 ODF 30"

EGSE-1-1/2-Z 3X4 ODF 5' SBFJ-A-C 3X4 ODF 30" SBFVE-A-Z 3X4 ODF 30" EBFVE-B-CP100 3X4 ODF 30"

EGSE-1-1/2-ZP 3X4 ODF 5' SBFJ-B-C 3X4 ODF 30" SBFVE-A-ZP 3X4 ODF 30" EBFVE-B-Z 3X4 ODF 30"

EGSE-1-C 3X4 ODF 5' SBFJE-AAA-C 3X4 ODF 30" SBFVE-A-ZP40 3X4 ODF 30" EBFVE-B-ZP40 3X4 ODF 30"

EGSE-1-X 3X4 ODF 5' SBFJE-AA-C 3X4 ODF 30" SBFVE-B-C 3X4 ODF 30" EBFVE-C-C 3X4 ODF 30"

EGSE-1-Z 3X4 ODF 5' SBFJE-A-C 3X4 ODF 30" SBFVE-B-Z 3X4 ODF 30" EBFVE-C-CP100 3X4 ODF 30"

EGSE-1-ZP 3X4 ODF 5' SBFJE-B-C 3X4 ODF 30" SBFVE-B-ZP40 3X4 ODF 30" EBFVE-C-ZP40 3VX4 ODF 30"

EGSE-2-C 3X4 ODF 5' SBFJE-C-C 3X4 ODF 30" SBFVE-C-C 3X4 ODF 30"

EGSE-2-ZP 3X4 ODF 5' SBFP-AAA-C 3X4 ODF 30" SBFVE-C-Z 3X4 ODF 60"

EGV-1/2-C 3X4 ODF 5' SBFVE-C-ZP40 3X4 ODF 30"

EGV-1/2-Z 3X4 ODF 5'

IMPORTANT NOTES:

E – Elbow Inlet

V – 877 Series (100 Mesh) Strainer



637

THER

MOST

ATIC

EXP

ANSI

ON V

ALVE

S

PART NO*



SPORLAN MODEL**

TYPE KT KT-43-FC 5’(1.5M) ELEMENT

KT-43-FZ 5’(1.5M) ELEMENT

KT-43-FZP 5’(1.5M) ELEMENT

KT-43-PC 5’ ELEMENT

KT-43-RC 5’(1.5M) ELEMENT

KT-43-RZ 30"(.75M) ELEMENT

TYPE S

TYPE EMC

KT-43-RZP 5’(1.5M) ELEMENT

SRE-1/2-C 4X5 ODF 5' EMC-10-PC 3X4 ODF 5' KT-43-VC 5’(1.5M) ELEMENT

SRE-1/2-ZP 4X5 ODF 5' EMC-10-SC 3X4 ODF 5' KT-43-VZ 5’(1.5M) ELEMENT

SRE-1-1/2-C 4X5 ODF 5' EMC-10-SZ 3X4 ODF 5' KT-43-VZP 5’(1.5M) ELEMENT

SRE-1-1/2-Z 4X5 ODF 5' EMC-10-VC 3X4 ODF 5' KT-53-FC 5’ ELEMENT

SRE-1-1/2-ZP 4X5 ODF 5' EMC-10-VZ 3X4 ODF 5' KT-53-FZ 5’(1.5M) ELEMENT

SRE-1-C 4X5 ODF 5' EMC-11-SZ 3X4 ODF 5' KT-53-FZP 5’(1.5M) ELEMENT

SRE-1-ZP 4X5 ODF 5' EMC-20-PC 3X4 ODF 5' KT-53-RC 5’ ELEMENT

SRE-2-L1 4X5 ODF 5' EMC-20-SC 3X4 ODF 5' KT-53-SZ 5’ ELEMENT

SRE-4-Z 4X7 ODF 5' EMC-20-VC 3X4 ODF 5' KT-53-SZP 5’ ELEMENT

SSE-1/4-C 3X4 ODF 5' EMC-21-PC 3X4 ODF 5' KT-53-VC 5’ ELEMENT

SSE-10-ZP 5X7 ODF 5' EMC-21-SC 3X4 ODF 5' KT-53-VZ 5’(1.5M) ELEMENT

SSE-10-ZP 7X9 ODF 5' EMC-21-VC 3X4 ODF 5' KT-53-VZP 5’(1.5M) ELEMENT

SSE-2-C 4X5 ODF 5' EMCE-10-JC 3X4 ODF 5' KT-83-FC 5’ ELEMENT

SSE-2-ZP 4X5 ODF 5' EMCE-10-PC 3X4 ODF 5' KT-83-SC 5’ ELEMENT

SSE-3-C 4X7 ODF 5' EMCE-10-SC 3X4 ODF 5' KT-83-SZ 5’ ELEMENT

SSE-3-L1 4X7 ODF 5' EMCE-10-SZ 3X4 ODF 5' KT-83-SZP ELEMENT

SSE-3-ZP 4X7 ODF 5' EMCE-10-VC 3X4 ODF 5' KT-83-VC 5’ ELEMENT

SSE-3-ZP40 4X7 ODF 5' EMCE-10-VZ 3X4 ODF 5' KT-45-ZGA, 30" ELEMENT

SSE-4-C 4X7 ODF 5' EMCE-11-SZ 3X4 ODF 5'

SSE-4-ZP 4X7 ODF 5' EMCE-11-VZ 3X4 ODF 5'

SSE-6-C 4X7 ODF 5' EMCE-12-SC 3X4 ODF 5'

SSE-6-C 5X7 ODF 5' EMCE-12-SZ 3X4 ODF 5'

SSE-6-X 5X7 ODF 5' EMCE-12-VC 3X4 ODF 5'

SSE-6-Z 5X7 ODF 5' EMCE-12-VZ 3X4 ODF 5'

SSE-6-ZP 5X7 ODF 5' EMCE-13-SZ 3X4 ODF 5'

SSE-7-C 5X7 ODF 5' EMCE-13-VZ 3X4 ODF 5'

SSE-7-ZP 5X7 ODF 5' EMCE-20-JC 3X4 ODF 5'

SVE-1/2-C 4X5 ODF 5' EMCE-20-PC 3X4 ODF 5'

SVE-10-C 5X7 ODF 5' EMCE-20-SC 3X4 ODF 5'

SVE-1-1/2-C 4X5 ODF 5' EMCE-20-VC 3X4 ODF 5'

SVE-1-1/2-L1 3X4 ODF 5' EMCE-21-JC 3X4 ODF 5'

SVE-1-1/2-Z 3X4 ODF 5' EMCE-21-PC 3X4 ODF 5'

SVE-1-1/2-ZP40 4X5 ODF 5' EMCE-21-SC 3X4 ODF 5'

SVE-15-C 7X11 ODF 5' EMCE-21-VC 3X4 ODF 5'

SVE-15-CP100 7X9 ODF 5' EMCE-22-JC 3X4 ODF 5'

SVE-1-C 4X5 ODF 5' EMCE-22-PC 3X4 ODF 5'

SVE-1-ZP40 4X5 ODF 5' EMCE-22-SC 3X4 ODF 5'


SVE-2-L1 4X5 ODF 5' EMCE-23-PC 3X4 ODF 5'

SVE-2-ZP40 4X5 ODF 5' EMCE-23-SC 3X4 ODF 5'


SVE-3-L1 4X5 ODF 5'

SVE-3-L2 4X5 ODF 5'

SVE-3-ZP40 4X5 ODF 5'

SVE-4-C 4X7 ODF 5'

SVE-4-L1 4X7 ODF 5'

SVE-4-X 4X7 ODF 5'

SVE-4-ZP40 4X7 ODF 5'

SVE-5-C 4X7 ODF 5'

SVE-8-C 5X7 ODF 5'

SVE-8-L1 5X7 ODF 5'

SVE-8-Z 5X7 ODF 5'

IMPORTANT NOTES: A. R-134a air conditioning and commercial refrigeration applications are using R-12 or R-409A or R-401A elements. B. R-404A commercial refrigeration applications are using R-502 or R-408A elements. C. R-404A and R-507 low temperature refrigeration applications are using R-502 or R-402A or R-408A elements.



638

THERMOSTATIC EXPANSION VALVES SPORLAN THERMOSTATIC EXPANSION VALVESQUICK REFERENCE GUIDE — AIR CONDITIONING VALVES

NOMINAL CAPACITY RANGE (Tons)

VALVE TYPE R-22

R-134a

R-404A &

R-507

CONNECTION

TYPES

VALVE DESCRIPTION AND APPLICATION

2 thru 6

—

—

ODF Solder

Compact and adjustable thermostatic expansion valve with an internal check valve to allow reverse flow on heat pump applications. Valve also can be used for

refrigerant 410A applications.(2 ton through 6 ton) RC valve replaces RI valve.

2 thru 10

2 thru 6

2 thru 7

ODF Solder

Brass bar body, externally adjustable valve. Inlet has a permanent 12 mesh strainer. General purpose valve for

air conditioning and refrigeration applications.

8 & 11

5 & 7

6 & 7-1/2

Extended ODFSolder

Same physical size as the Type S valve except it features extended ODF connections and a balanced

port construction.

15 thru 70

9 thru 40

9 thru 45

ODF Solder

Brass bar body, externally adjustable valve. Inlet has a permanent 12 mesh strainer. General purpose valve for

air conditioning and refrigeration applications.

52 thru 100

35 thru 55

38 thru 70

ODF Solder or FPT Flange

Cast bronze body, externally adjustable valve with flange connections. Inlet has a 12 mesh strainer. This valve type features a dual port semi-balanced design. This valve type provides valve capacities greater than

the Type M, and is suitable for air conditioning and refrigeration applications. Flanges for the Type V are

interchangeable with the Type M.

135 & 180

80 & 110

—

ODF Solder Flange

Cast bronze body, externally adjustable valve with flange connections. Inlet has a 12 mesh strainer. This valve type features a dual port semi-balanced design and it is primarily for large capacity chillers. This valve type provides the largest valve capacities available for

flange connection TEVs.

• R-22 M Valves With GA & CP 100 Thermostatic chargers are also available


639

THER

MOST

ATIC

EXP

ANSI

ON V

ALVE

S SPORLAN THERMOSTATIC EXPANSIONVALVESType-S

ELEMENT SIZE No. 83, Knife Edge Joint. Standard Tubing Length 5 Feet.

STANDARD CONNECTIONS (in. ODF Solder)

REFRIGERANT (Sporlan Code)

TYPE & CAPACITY

TH

ER

MO

ST

AT

IC

CH

AR

GE

S

AV

AIL

AB

LE

Inlet

Outlet

SVE-2 SVE-3

5/8

SVE-4 SVE-5

1/2

SVE-8

22 (V)

SVE-10

GA or CP100

5/8

7/8

Type-EBSBalanced Port Construction ELEMENT SIZE No. 83, Knife Edge Joint, Standard Tubing Length 5 Feet

TYPE &

CAPACITY

STANDARD CONNECTIONS (in. Extended ODF Solder)

REFRIGERANT (SPORLAN

CODE) External Equalizer

Only TH

ER

MO

ST

AT

IC

CH

AR

GE

S

AV

AIL

AB

LE

Inlet

Outlet

EBSVE-8 22 (V) EBSVE-11

GA or CP100

5/8

7/8

Type-OBalanced Port Construction ELEMENT SIZE No. 83 and 33, Knife Edge Joint, Standard Tubing Length 5 Feet

STANDARD CONNECTIONS

(in. ODF Solder)

REFRIGERANT (Sporlan

Code) TY

PE

&

CA

PA

CIT

Y

EL

EM

EN

T

SIZ

E

NU

MB

ER

TH

ER

MO

ST

AT

IC

CH

AR

GE

S

Inlet

Outlet

OVE-15 1-1/8 OVE-20

7/8

OVE-30

83

OVE-40 OVE-55

22 (V)

OVE-70

33

GA or CP100

1-1/8

1-3/8

With internal check valve. R-22 ELEMENT SIZE No. 43, Knife Edge Joint, Standard Tubing Length 30 Inches R-410A ELEMENT SIZE No. 45, Knife Edge Joint, Standard Tubing Length 30 Inches

TYPE &

CAPACITY

STANDARD CONNECTIONS(In. ODF Solder)

REFRIGERANT(Sporlan Code)

External Equalizer

Only

TH

ER

MO

ST

AT

IC

CH

AR

GE

S

AV

AIL

AB

LE

Inlet

Outlet

RCVE-2 RCVE-3

3/8

RCVE-4

1/2

RCVE-5

22 (V)

RCVE-6

1/2

5/8 RCZE-2 RCZE-3

3/8

RCZE-4

1/2

RCZE-5

410A (Z)

RCZE-6

GA Only

1/2

5/8

ELEMENT SIZE No. 63, Small Capacity No. 7 Large Capacity —Gasket Joint, Standard Tubing Length 10 Feet, Flange Ring Size —2-3/4” OD x 3-3/16” ID.

TY

PE

&

CA

PA

CIT

Y

STANDARD CONNECTIONS(in. ODF Solder)

REFRIGERANT(Sporlan

Code)

Ext

ern

al E

qu

aliz

er

On

ly

EL

EM

EN

T

SIZ

E

NU

MB

ER

TH

ER

MO

ST

AT

IC

CH

AR

GE

S

AV

AIL

AB

LE

Inlet

Outlet

WVE-135

63 GA or CP100

22(V)

WVE-180

7 G only

1-5/8

2-1/8

ELEMENT SIZE No. 63, Gasket Joint, Standard Tubing Length 5 Feet Flange Ring Size — 1-3/4” OD x 1-1/2” ID.

Type &

CAPACITY

STANDARD CONNECTIONS

(In. Extended ODF Solder)

REFRIGERANT (Sporlan Code) External

Equalizer Only

TH

ER

MO

ST

AT

IC

CH

AR

GE

S

AV

AIL

AB

LE

Inlet

Outlet

VVE-52 VVE-70

22 (V)

VVE-100

GA or CP10

0

1-3/8

1-3/8

TEV REPLACEMENT ELEMENTS

Item Descriptions

KT-43-VGA 30” KT-43-VCP100 30”

KT-33-VGA 60” KT-33-VCP100 60”

KT-53-VGA 60” KT-53-VCP100 60”

KT-83-VGA 60” KT-83-VCP100 60”

KT-63-VGA 10” KT-63-VCP100 10”

Type-RC

Type-W

Type-V


640

THERMOSTATIC EXPANSION VALVES THERMOSTATIC EXPANSION VALVE CAPACITIES FOR REFRIGERANTS (Tons of Refrigeration)AIR CONDITIONING AND HEAT PUMP APPLICATIONS

REFRIGERANT

22 410A

RECOMMENDED THERMOSTATIC CHARGES

VCP100, VGA N, ZGA

EVAPORATOR TEMPERATURE (°F)

VALVE TYPES

NOMINAL CAPACITY

40° 40°

RC 2 2.30 2.76

RC 3 3.20 3.83

RC 4 4.20 5.03

RC 5 5.00 5.99

RC 6 6.01 7.20

EBS 8 8.51 —

EBS 11 11.50 —

O 15 15.00 —

O 20 22.20 —

O 30 30.50 —

O 40 40.30 —

O 55 55.00 —

O 70 73.00 —

S 2 2.00 —

S 3 3.20 —

S 4 4.50 —

S 5 5.20 —

S 8 8.00 —

S 10 10.00 —

S 15 15.00

V 52 52.00 —

V 70 73.00 —

V 100 100.00 —

W 135 143.00 —

W 180 180.00 —

LIQUID TEMPERATURE ENTERING TEV (°F)

60° 70° 80° 90° 100° 110° 120° 130° 140° REFRIGERANT

CORRECTION FACTOR, CF LIQUID TEMPERATURE 22 1.23 1.17 1.12 1.06 1.00 0.94 0.88 0.82 0.76

410A 1.32 1.24 1.16 1.08 1.00 0.92 0.83 0.73 0.62

These factors include corrections for liquid refrigerant density and net refrigerating effect and are based on an evaporator temperature of 40° F.

PRESSURE DROP ACROSS TEV (PSI)

75 100 125 150 160 175 200 225 250 275

CORRECTION FACTOR, CF PRESSURE DROP REFRIGERANT

40°F EVAPORATOR TEMPERATURE 22 0.87 1.00 1.12 1.22 — 1.32 1.41 1.50 1.58 1.66

410A 0.68 0.79 0.88 0.97 1.00 1.05 1.12 1.19 1.25 1.31

TEV CAPACITY = TEV RATING X CF LIQUID TEMPERATURE X CF PRESSURE DROP —

Example: Calculate the actual capacity of a nominal 2 ton, R-22, Type RC valve at 40° F evaporator, 80° F liquid temperature enter-ing the TEV, and 75 psi pressure drop across the TEV:

TEV capacity = 2.30 (from rating chart) x 1.12 (CF liquid temperature) x 0.87 (CF pressure drop) = 2.24 tons


641

THER

MOST

ATIC

EXP

ANSI

ON V

ALVE

S SPORLAN THERMOSTATIC EXPANSION VALVEPART NUMBERSType S Series ValvesPart No DESCRIPTIONSVE-10-GA5/8X7/8ODF SVE-10-GA 5/8X7/8 ODFSVE-15-GA7/8X1-1/8ODF SVE-15-CP100 7/8X1-1/8 ODFSVE-2-GA1/2/5/8ODF SVE-2-GA 1/2X5/8 ODFSVE-3-GA1/2X5/8ODF SVE-3-GA 1/2X5/8 ODFSVE-4-GA1/2X7/8ODF SVE-4-GA 1/2X7/8 ODFSVE-5-GA1/2X7/8ODF SVE-5-GA 1/2X7/8 ODFSVE-8-GA5/8X7/8ODF SVE-8-GA 5/8X7/8 ODFSVE10CP1005/8X7/8ODF SVE-10-CP100 5/8X7/8 ODFSVE15CP1007/8X11/8OD SVE-15-CP100 7/8X1-1/8 ODFSVE2-CP1001/2X5/8OD SVE-2-CP100 1/2X5/8 ODFSVE3-CP1001/2X5/8OD SVE-3-CP100 1/2X5/8 ODFSVE4-CP1001/2X7/8OD SVE-4-CP100 1/2X5/8 ODFSVE5-CP1001/2X7/8OD SVE-5-CP100 1/2X5/8 ODFSVE8CP1005/8X7/8ODF SVE-8-CP100 5/8X7/8 ODF

Type RC Series ValvesPart No DESCRIPTIONRCVE-2-GA3/8X1/2ODF RCVE-2-GA 3/8X1/2 ODFRCVE-3-GA3/8X1/2ODF RCVE-3-GA 3/8X1/2 ODFRCVE-4-GA1/2X1/2ODF RCVE-4-GA 1/2X1/2 ODFRCVE-4-GA1/2X5/8ODF RCVE-4-GA 1/2X5/8 ODFRCVE-5-GA1/2X1/2ODF RCVE-5-GA 1/2X1/2 ODFRCVE-5-GA1/2X5/8ODF RCVE-5-GA 1/2X5/8 ODFRCVE-6-GA1/2X1/2ODF RCVE-6-GA 1/2X1/2 ODFRCVE-6-GA1/2X5/8ODF RCVE-6-GA 1/2X5/8 ODFRCZE-2-GA3/8X1/2ODF RCZE-2-GA 3/8X1/2 ODFRCZE-3-GA3/8X1/2ODF RCZE-3-GA 3/8X1/2 ODFRCZE-4-GA1/2X1/2ODF RCZE-4-GA 1/2X1/2 ODFRCZE-5-GA1/2X5/8ODF RCZE-5-GA 1/2X5/8 ODFRCZE-6-GA1/2X5/8ODF RCZE-6-GA 1/2X5/8 ODF

Part No DESCRIPTIONEBSVE-11-GA5/8X7/8OD EBSVE-11-GA 5/8X7/8 ODFEBSVE-8-CP1005/8X7/8 EBSVE-8-C100 5/8X7/8 ODFEBSVE-8-GA5/8X7/8ODF EBSVE-8-GA 5/8X7/8 ODFEBSVE11CP1005/8X7/8O EBSVE-11-CP100 5/8X7/8 ODF

Part No DESCRIPTIONOVE-20-GA7/8X7/8ODF TXV, VALVE 7/8X7/8 ODFOVE15CP1007/8X11/8O OVE-15-CP100 7/8X1-1/8 ODFOVE15GA7/8X1-1/8ODF OVE-15-GA 7/8X1-1/8 ODFOVE20CP1007/8X1-3/8OD OVE-20-CP100 7/8X1-3/8 ODFOVE20GA7/8X1-1/8ODF OVE-20-GA 7/8X1-1/8 ODFOVE30CP1001-1/8X1-3/8O OVE-30-CP100 1-1/8X1-3/8 ODFOVE30GA1-1/8X1-3/8OD OVE-30-GA 1-1/8X1-3/8 ODFOVE40CP10011/8X13/8O OVE-40-CP100 1-1/8X1-3/8 ODFOVE40CP10011/8X15/8O OVE-40-CP100 1-1/8X1-5/8 ODFOVE40GA1-1/8X1-3/8OD OVE-40-GA 1-1/8X1-3/8 ODFOVE40GA1-1/8X1-5/8OD OVE-40-GA 1-1/8X1-5/8 ODFOVE55CP10011/8X13/8O OVE-55-CP100 1-1/8X1-3/8 ODFOVE55CP10011/8X15/8O OVE-55-CP100 1-1/8X1-5/8 OOVE55GA1-1/8X1-3/8OD OVE-55-GA 1-1/8X1-3/8 ODFOVE55GA1-1/8X1-5/8OD OVE-55-GA 1-1/8X1-5/8 ODFOVE70CP10011/8X13/8O OVE-70-CP100 1-1/8X1-3/8 ODFOVE70CP10011/8X15/8O OVE-70-CP100 1-1/8X1-5/8 ODFOVE70GA1-1/8X1-3/8OD OVE-70-GA 1-1/8X1-3/8 ODFOVE70GA1-1/8X1-5/8OD OVE-70-GA 1-1/8X1-5/8 ODF

Part No DESCRIPTIONVVE-100-GA13/8X13/8 VVE-100-GA 1-3/8X1-3/8 ODFVVE-52-GA13/8X138OD VVE-52-GA 1-3/8X1-3/8 ODFVVE-70-GA13/8X13/8OD VVE-70-GA 1-3/8X1-3/8 ODFVVE100CP10013/8X13/8 VVE-100-CP100 1-3/8X1-3/8 ODFVVE52CP10013/8X13/8 VVE-52-CP100 1-3/8X1-3/8 ODFVVE70CP10013/8X13/8O VVE-70-CP100 1-3/8X1-3/8 ODF

Part No DESCRIPTIONWVE-135-GA15/8X21/8 WVE-135GA 1-5/8X2-1/8 ODFWVE135CP10015/8X21/8 WVE-135-CP100 1-5/8X2-1/8 ODF

Type EBS Series Valves

Type O Series Valves

Type V Series Valves

Type W Series Valves


642

SOLENOID VALVES SPORLAN SOLENOID VALVES

Refrigerants 22, 134a, 402A, 404A, 407C, 502, 507 SPECIFICATIONS

6 Proven Benefits of Sporlan Solenoid Valves

• Molded coil for most sizes.

• Class “F” temperature rating – Coil types MKC-1, OMKC-1, MKC-2, and OMKC-2.

• Extremely rugged, simple design – few parts.

• “E” Series may be brazed without disassembly.

• Tight closing through use of synthetic seating material.

• Can be used on Refrigerants 22, 134a, 401A, 402A, 404A, 407C, 502 and 507 because of high MOPD ratings.

Sporlan Solenoid Valves are made in two general types, normally closed and normally open. The normally closed types may be further sub-divided into direct acting and pilot operated types.

The Sporlan “E” series solenoid valves feature extended solder type connections as standard. One important benefit to the user is that all valves in the “E” series can be installed without disassembly using either low or no silver content brazing alloy. The “E” series is interchangeable with the “B” series; solder type valves, providing the overall length can be accommodated.

All valves in the “E” series have the same capacities as the “B” series with the exception of the E42. Its capacity is approximately 15% greater than the MA42.

All Sporlan solenoid valves are designed for liquid, suction and discharge gas applications.

Most Sporlan Solenoid Valves are listed by Underwriters’ Laboratories, Inc. –Guide No. Y10Z – File No.MH4576 and Canadian Standards Association –Guide 440-A-O, Class 3221, File 19953 and CE provisions of the LVD 73/23/EEC.

LIQUID CAPACITY SELECTION TABLE

PART NO TONS OF REFRIGERATION** R-22 R-134a R-401A R-402A

PRESSURE DROP – psi* “E”

SERIES VALVE 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

E3 0.9 1.3 1.6 1.9 2.1 0.8 1.2 1.5 1.8 2.0 0.9 1.3 1.6 1.9 2.1 0.6 0.9 1.1 1.2 1.4 E5 1.6 2.3 2.8 3.3 3.6 1.5 2.1 2.6 3.0 3.4 1.6 2.3 2.8 3.3 3.7 1.1 1.5 1.9 2.1 2.4 E6 2.9 4.0 4.9 5.7 6.4 2.7 3.8 4.6 5.3 5.9 2.9 4.1 4.9 5.7 6.4 1.9 2.7 3.3 3.8 4.2 E9 4.7 6.6 8.1 9.3 10.4 4.4 6.2 7.5 8.7 9.7 4.7 6.6 8.1 9.3 10.4 3.1 4.4 5.3 6.2 6.9

E10 6.4 9.1 11.1 12.8 14.3 6.0 8.5 10.4 12.0 13.4 6.4 9.1 11.1 12.8 14.4 4.2 6.0 7.3 8.5 9.4 E14 9.1 12.9 15.8 18.2 20.3 8.5 12.0 14.7 17.0 18.9 9.1 12.9 15.8 18.2 20.4 6.0 8.5 10.4 12.0 13.4E19 13.9 19.8 24.2 28.0 31.4 13.0 18.4 22.6 26.1 29.2 14.0 19.8 24.3 28.1 31.4 9.2 13.0 16.0 18.5 20.7E25 23.8 33.8 41.4 47.8 53.5 22.2 31.5 38.6 44.6 49.9 23.9 33.8 41.4 47.9 53.6 15.7 22.2 27.3 31.5 35.3E34 33.2 47.0 57.6 66.5 74.4 31.0 43.8 53.7 62.0 69.4 33.3 47.1 57.7 66.6 74.5 21.9 31.0 38.0 43.9 49.0— 60.9 82.3 98.2 111 123 56.7 76.7 91.5 104 114 61.0 82.5 98.0 112 123 40.4 54.6 65.1 73.8 81.4

E42 73.5 104 127 147 164 68.6 96.9 119 137 153 73.6 104 127 147 165 48.5 68.5 83.9 96.9 108 — 109 147 175 199 219 101 137 163 185 204 109 147 176 199 220 72.1 97.5 116 132 145

PART NO TONS OF REFRIGERATION**

404A 407C 502 507 PRESSURE DROP – psi*

“E” SERIES VALVES 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5

E3 0.6 0.9 1.1 1.2 1.4 0.8 1.2 1.5 1.7 1.9 0.6 0.8 1.0 1.2 1.4 0.6 0.8 1.0 1.2 1.4 E5 1.1 1.5 1.9 2.1 2.4 1.5 2.1 2.6 3.0 3.4 1.0 1.5 1.8 2.1 2.4 1.0 1.5 1.8 2.1 2.4 E6 1.9 2.7 3.3 3.8 4.2 2.6 3.7 4.5 5.2 5.8 1.9 2.6 3.2 3.7 4.1 1.9 2.6 3.2 3.7 4.1 E9 3.1 4.4 5.4 6.2 6.9 4.3 6.1 7.4 8.6 9.6 3.0 4.3 5.2 6.0 6.8 3.0 4.3 5.2 6.0 6.7 E10 4.2 6.0 7.3 8.5 9.5 5.9 8.3 10.2 11.8 13.2 4.2 5.9 7.2 8.3 9.3 4.2 5.9 7.2 8.3 9.3 E14 6.0 8.5 10.4 12.0 13.4 8.4 11.8 14.5 16.7 18.7 5.9 8.4 10.2 11.8 13.2 5.9 8.3 10.2 11.8 13.2E19 9.2 13.1 16.0 18.5 20.7 12.8 18.2 22.3 25.8 28.8 9.0 12.8 15.7 18.2 20.3 9.0 12.8 15.7 18.1 20.3E25 15.7 22.3 27.4 31.6 35.4 21.9 31.0 38.0 44.0 49.2 15.5 21.9 26.8 31.0 34.7 15.4 21.8 26.8 30.9 34.6E34 22.0 31.1 38.1 44.0 49.2 30.5 43.2 53.0 61.2 68.4 21.5 30.5 37.4 43.2 48.3 21.5 30.4 37.3 43.1 48.2— 40.8 55.2 65.8 74.6 82.2 56.4 76.3 91.1 103 114 39.5 53.4 63.7 72.2 79.5 39.8 53.8 64.2 72.8 80.2

E42 48.6 68.8 84.2 97.2 109 67.6 95.6 117 135 151 47.7 67.4 82.5 95.3 107 47.6 67.3 82.4 95.1 106 — 72.8 98.5 118 133 147 101 136 163 184 203 70.4 95.3 114 129 142 71.0 96.1 115 130 143

*Do not use below 1 psi pressure drop, except Types E3 and A3 valves. **Capacities are based on 40° F evaporator and 100° F liquid. Valve types whether Normally Closed or Normally Open have the same capacities, i.e., B10 or OB10, E10 or OE10.

Solenoid valves for brine applications – consult Sporlan Valve Company, Washington, MO.

SOLENOID VALVES

643

SOLE

NOID

VAL

VES

SPORLAN SOLENOID VALVESSPECIFICATIONSRefrigerants 22, 134a, 402A, 404A, 407C, 502, 507

PART NOE Series Extended Connections Without Manual Lift Stem With Manual Lift Stem Normally Closed CONNECTIONS (in) PORT SIZE (in) MOPD psi AC WATTSE3S120 — — .101 300 10E3S130 — 3/8 ODF Solder .101 300 10E5S120 — 1/4 ODF Solder .150 300 10E5S130 — 3/8 ODF Solder .150 300 10E6S130 ME6S130 3/8 ODF Solder 3/16 300 10E6S140 ME6S140 1/2 ODF Solder 3/16 300 10E9S240 ME9S240 1/2 ODF Solder 9/32 300 15E10S240 ME10S240 1/2 ODF Solder 5/16 300 15E10S250 ME10S250 5/8 ODF Solder 5/16 300 15E14S250 ME14S250 5/8 ODF Solder 7/16 300 15E19S250 ME19S250 5/8 ODF Solder 19/32 300 15E19S270 ME19S270 7/8 ODF Solder 19/32 300 15E25S270 ME25S270 7/8 ODF Solder 25/32 300 15E25S290 ME25S290 1-1/8 ODF Solder 25/32 300 15E34S290 ME34S290 1-1/8 ODF Solder 1 300 15E34S2110 ME34S2110 1-3/8 ODF Solder 1 300 15E42S2130 ME42S2130 1-5/8 ODF Solder 1-5/16 300 15E42S2170 ME42S2170 2-1/8 ODF Solder 1-5/16 300 15

SOLENOID PARTS KITS Part No.

KS-B6/E6 KS-B19/E19

KS-B9/E9 KS-B25/E25

KS-B10/E10 KS-B34/E34

KS-B14/E14 KS-B42/E42

SOLENOID COILS Coil Type and Voltage

MKC-1 and MKC-2 – 24 JAQ and CAQ

MKC-1 and MKC-2 – 120 JAM and CAM

MKC-1 and MKC-2 – 208-240 JAN and CAN MKC-1 and MKC-2 – Dual JAU and CAU

SOLENOID VALVES

644

THREE-WAY HEAT RECLAIM VALVES

THREE WAY HEAT RECLAIM VALVES

Sporlan Heat Reclaim Valves are tight synthetic seating three way valves designed specifically to divert hot gas from the normal to

auxiliary condenser.

OPERATION

“B” TYPE

Normal (Outdoor) Condenser – De-energized – With the pilot valve de-energized, high side pressure is prevented from entering the cavity above the piston-seat assembly. At the same time the upper pilot port is opened to suction pressure. The resulting pressure differential across the piston moves the piston-seat assembly to close the reclaim (upper) main port. When the upper pilot port is open, the cavity above the piston is open to suction. Pump out of the reclaim condenser is controlled by the bleed rate through the piston. After the reclaim condenser has been pumped out, and the valve continues to operate in the normal condenser mode, all flow ceases, thus eliminating high to low side bleed and the resulting capacity loss.

“C” TYPE Normal (Outdoor) Condenser – De-energized – With the pilot valve de-energized, high side pressure is prevented from entering cavity above the piston-seat assembly. At the same time the upper pilot port is opened to suction pressure. The resulting pressure differential across the piston moves the piston-seat assembly to close the reclaim (upper) main port. The non bleed piston prevents high to low side bleed with the system operating in the normal condenser mode. “B” AND “C” TYPE Reclaim (Reheat) Condenser – Energized – When the pilot valve is energized, high side pressure is permitted to flow thru the lower pilot port. At the same time the upper pilot port is closed to suction. High side pressure on top of the piston moves the piston-seat assembly to close the normal condenser port and open the reclaim (upper) main port. With the upper pilot port closed there is no high to low side bleed loss with the system operating in the reclaim mode.

HEAT RECLAIM SYSTEMS

PART NO* Sporlan Model

10G711B 120/50-60 JAM

10G79B 120/50-60 JAM

12D11B LESS COIL

12D11C LESS COIL

12D13B LESS COIL

12D13B-SC LESS COIL

12D13C LESS COIL

16D17B LESS COIL

16D17B-SC LESS COIL

16D17C LESS COIL

8D7B 208-240/50-60 JAN 8D7B DUAL JAU 8D7C LESS COIL 8D9B DUAL JAU 8D9B LESS COIL 8D9B-CV 24/50-60 LAQ

• With Head Pressure Control

• With Split Condenser Control

• With Integral Check Valve

When employing heat reclaim on a refrigeration system, the addition of head pressure controls is important not only to maintain liquid pressure at the expansion valve inlet, but also to assure availability of quality hot gas at the reclaim heat exchanger. Split condenser controls are important to minimize the required refrigerant charge for wintertime operation. And, integral check valves are important to minimize installation costs.

8D9C LESS COIL

Note: SC - split condenser; CV - check valve.

*( ) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.

THREE-WAY HEAT RECLAIM VALVES

645

FILT

ER D

RIER

S SPORLAN CATCH-ALL SEALED TYPEThe universal acceptance of the Catch-All Filter Drier is due to its unique molded porous core, consisting of a blend of highly effective desiccants. The quality features built into it assure years of service on any refrigeration system.

MOISTURE — The Catch-All Filter Drier removes moisture from the refrigerant by adsorbing and retaining it deep within the desiccant granules.

FOREIGN MATTER — The Catch-All Filter Drier will filter out scale, solder particles, carbon, sludge, dirt, or any other foreign matter with negligible pressure drop. Fine particles that would go through an ordinary strainer are removed down to a minimum size in one pass filtration. The large filtering area of the Catch-All Filter Drier core permits it to collect a large amount of dirt without plug up.

OIL SLUDGE AND VARNISH — Even the best refrigeration oils break down to produce varnish, sludge, and organic acids. Only the Catch-All Filter Drier is capable of removing these products of oil decomposition.

ACID — The Catch-All Filter Drier is unexcelled in acid removal ability. The hydrochloric, hydrofluoric, and various organic acids are adsorbed and held by the desiccant in a manner similar to the adsorption of moisture. Tests have demonstrated that the Catch-All Filter Drier will remove over 10 times as much acid as the desiccant used in most driers. This ability, along with its excellent ability to clean up the oil, is responsible for the excellent field performance in cleaning up severely contaminated systems.SPECIAL APPLICATIONS — A special “HH” core Catch-All Filter Drier is available to remove wax which frequently causes difficulty on low temperature Refrigerant 22 and 502 systems. For cap tube systems, use the C-032-CAP or CW-032-CAP Catch-All which has fittings suitable for attaching to any size capillary tube. Remember…It’s not how much moisture you remove from a refrigeration system that counts, it’s how little moisture is left

SEALED TYPE – Liquid Line and Suction Line

SPECIFICATIONS

Listed by Underwriters Laboratories Inc. – Guide SMGT-File No. SA-1756A& B. Maximum Rated Pressure of 650 psi, except for the C-140 Series which has a maximum pressure of 450 psi.

LIQUID LINE TYPE

SUCTION LINE TYPE

OVERALL LENGTH (in.)

SAE Flare ODF Solder ODF Solder

CONNECTION

SIZE (in.)

VOLUME OF DESICCANT

(cu in.) SAE Flare ODF Solder

SOLDER SOCKET

DEPTH (in.)

DIAMETER

of BODY (in.)

C-032 C-032-S — 1/4 4.19 3.81 0.38 C-033 C-033-S — 3/8

3 4.69 3.88 0.44

1.75

C-052 —

C-053

C-052-S C-0525-S C-053-S

—

1/4 5/16 3/8

5

4.75 —

5.19

4.19 4.38 4.31

0.38 0.44 0.44

2.44

C-082

— C-083 C-084

C-082-S C-0825-S C-083-S C-084-S

— — — C-084-S-T-HH

1/4 5/16 3/8 1/2

9

5.62 —

6.06 6.31

5.12 5.31 5.25 5.44

0.38 0.44 0.44 0.50

2.62

C-162 —

C-163 C-164 C-165

— —

C-162-S C-1625-S C-163-S C-164-S C-165-S

— C-167-S

— — — C-164-S-T-HH C-165-S-T-HH C-166-S-T-HH C-167-S-T-HH

1/4 5/16 3/8 1/2 5/8 3/4 7/8

16

6.25 —

6.75 6.94 7.25 — —

5.75 5.94 5.88 6.00 6.31 6.75 6.93

0.38 0.44 0.44 0.50 0.62 0.62 0.75

3.00

C-303 C-304 C-305

— — —

C-303-S C-304-S C-305-S C-306-S C-307-S C-309-S

— — C-305-S-T-HH C-306-S-T-HH C-307-S-T-HH C-309-S-T-HH

3/8 1/2 5/8 3/4 7/8

1-1/8

30

9.69 9.88 10.19

— — —

8.88 9.00 9.25 9.65 9.80 9.75

0.44 0.50 0.62 0.62 0.75 0.96

3.00

C-413 C-414 C-415

— —

— C-414-S C-415-S C-417-S C-419-S

— — — C-417-S-T-HH C-419-S-T-HH

3/8 1/2 5/8 7/8

1-1/8

41

9.56 9.94 10.25

— —

— 9.05 9.35 9.81 9.75

— 0.50 0.62 0.75 0.90

3.50

—

—

C-437-S-T-HH C-439-S-T-HH C-4311-S-T-HH C-4313-S-T-HH

7/8 1-1/8 1-3/8 1-5/8

48

— 10.34 10.62 10.94 10.94

0.75 0.94 1.00 1.06

4.75

— C-607-S C-609-S

C-607-S-T-HH C-609-S-T-HH

7/8 1-1/8

60

— 16.00 16.00

0.75 0.90

3.00

COMPACT STYLE

C-144-S-TT-HH C-145-S-TT-HH C-146-S-TT-HH C-147-S-TT-HH C-149-S-TT-HH

1/2 5/8 3/4 7/8

1-1/8

14

—

4.14 4.38 4.83 4.97 4.93

0.50 0.66 0.66 0.75 0.96

4.44

FILTER DRIERS

646

FILTER DRIERS SPORLAN CATCH-ALL REPLACEABLE CORE TYPE

The rugged construction of the Replaceable Core Catch-All has proven itself in the field for many years. The design features include:

1. The famous molded porous core for maximum contaminant removal. The core cannot swell, powder, or pack—assuring ease of installation and removal; 2. The bolt and nut attachment of the end plate provides simple and trouble free installation; 3. The internal construction gives a one piece assembly and assures proper core alignment;

4. A complete line of fitting sizes — all with copper fittings; 5. No plastic parts are used — all internal parts are plated steel; 6. A corrosion resistant powder paint protects the exterior of the shell.

REPLACEABLE CORE TYPETYPE CONNECTIONS (in)

ODF SolderNUMBER OF

CORESCORE PART NO VOLUME OF

DESICCANT (cu in)MOUNTINGBRACKETS

OVERALLLENGTH (in)

C-485,C-485-G 5/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.15 C-485-T 5/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.15 C-487,C-487-G 7/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.30 C-487-T 7/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.30 C-489-T,C-489-G 1-1/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.50 C-4811-T,C-4811-G 1-3/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.60 C-4813-T,C-4813-G 1-5/8 1 RCW-48, RC-4864, or RC-4864-HH 48 A-685 9.60 C-967,C-967-G 7/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 14.84 C-967-T 7/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 14.84 C-969,C-969-G 1-1/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 15.04 C-969-T 1-1/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 15.04 C-9611-T,C-9611-G 1-3/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 15.14 C-9613-T,C-9613-G 1-5/8 2 RCW-48, RC-4864, or RC-4864-HH 96 A-685 15.14 C-1449,C-1449-G 1-1/8 3 RCW-48, RC-4864, or RC-4864-HH 144 A-685 20.58 C-1449-T 1-1/8 3 RCW-48, RC-4864, or RC-4864-HH 144 A-685 20.58 C-14411,C-14411-G 1-3/8 3 RCW-48, RC-4864, or RC-4864-HH 144 A-685 20.68 C-14411-T 1-3/8 3 RCW-48, RC-4864, or RC-4864-HH 144 A-685 20.68 C-14413-T,C-14413-G 1-5/8 3 RCW-48, RC-4864, or RC-4864-HH 144 A-685 20.68 C-19211,C-19211-G 1-3/8 4 RCW-48, RC-4864, or RC-4864-HH 192 A-685 26.22 C-19211-T 1-3/8 4 RCW-48, RC-4864, or RC-4864-HH 192 A-685 26.22 C-19213,C-19213-G 1-5/8 4 RCW-48, RC-4864, or RC-4864-HH 192 A-685 26.22 C-19213-T 1-5/8 4 RCW-48, RC-4864, or RC-4864-HH 192 A-685 26.22 C-30013,C-30013-G 1-5/8 3 RCW-100, RC-10098, or RC-10098-HH 300 A-175-2 26.22 C-30013-T 1-5/8 3 RCW-100, RC-10098, or RC-10098-HH 300 A-175-2 27.94 C-30017-T,C-30017-G 2-1/8 3 RCW-100, RC-10098, or RC-10098-HH 300 A-175-2 28.06 C-40017,C-40017-G 2-1/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 28.06 C-40017-T 2-1/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 34.56 C-40021-T,C-40021-G 2-5/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 34.57 C-40025-T,C-40025-G 3-1/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 34.44 C-40029-T,C-40029-G 3-5/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 34.81 C-40033-T,-C-40033-G 4-1/8 4 RCW-100, RC-10098, or RC-10098-HH 400 A-175-2 35.12

OPTIONAL SECONDARY FILTER – ORDER SEPARATELY Filter Part No. Description Quantity Required

FS-480 FS-960

FS-1440 Filter for C-480 Series Shell 1

FS-19200

FILTER DRIERS

647

FILT

ER D

RIER

S SPORLAN CATCH-ALL FILTER DRIERSLIQUID LINE RATINGS AND SELECTION RECOMMENDATIONS

RATINGS AT ARI STANDARD CONDITIONS SELECTION RECOMMENDATIONS (Tons)Water Capacity-Drops Refrigeration Air Conditioning

Refrigerant 22

60 PPM

Refrigerant 134a

50PPM

Refrigerant404A/507 50

PPM

Refrigerant407C

50 PPM

Refrigerant410A

50 PPM

Refrigerant Flow

Capacity** (Tons at 1 psi ΔP)

Commercial & Low Temperature Equipment

Field Replacementor Field Built Up

Systems

TYPE

SURFACE FILTERING

AREA

75°F 125° F 75° F 125° F 75° F 125° F 75° F 125° F 75° F 125° F 22 134a 404A507

407C 410A 12 & 134a

22 404A, 502& 507

12 &134a

22, 407C & 410A

C-032 C-032-CAP C-032-S C-032-F C-032-FM

1.5

1.3

1.0

1.3

1.4

C-033 3.5 3.2 2.3 3.2 3.4

C-033-S

9

61

50

67

48

71

58

52

17

27

20

3.8 3.5 2.6 3.5 3.7

1/4

1/4

1/4

1/2

1/2

C-052 C-052-S C-052-F C-052-FM

2.1

1.9

1.4

1.9

2.0

C-0525-S 3.4 3.1 2.3 3.1 3.3 C-053 4.1 3.8 2.7 3.8 4.0 C-053-S

15

146

119

158

114

169

138

123

40

63

48

4.7 4.3 3.1 4.3 4.5

1/3

1/3

1/3

3/4 thru

1

3/4 thru

2

C-082 C-082-S

2.1

1.9

1.4

1.9

2.0

C-0825-S 3.7 3.3 2.4 3.3 3.5 C-083 4.5 4.2 3.0 4.2 4.4

C-083-S 5.2 4.7 3.4 4.7 5.0 C-084 8.7 7.9 5.9 8.0 8.5 C-084-S

21

240

196

261

188

279

227

202

65

104

78

9.6 8.8 6.4 8.8 9.4

1/2 thru 1-1/2

1/2 thru 1-1/2

1/2 thru

1

3/4 thru

2

1

thru 2

C-162 C-162-S

2.1

1.9

1.4

1.9

2.0

C-1625-S 3.7 3.3 2.4 3.3 3.5 C-163 4.5 4.2 3.0 4.2 4.4 C-163-S 5.2 4.7 3.4 4.7 5.0

C-164 10.1 9.3 6.8 9.3 9.8 C-164-S 11.0 10.1 7.3 10.1 10.7 C-165 13.8 12.6 9.2 12.7 13.4 C-165-S

33

346

297

396

285

424

345

307

100

158

119

15.9 14.5 10.6 14.6 15.5

1

thru 2

1-1/2 thru

3

3/4 thru

2

1

thru 5

1-1/2 thru

5

C-303 4.6 4.2 3.0 4.2 4.4 C-303-S 5.3 4.7 3.4 4.7 5.0 C-304 10.1 9.3 6.8 9.3 9.8 C-304-S 11.0 10.1 7.3 10.1 10.7

C-305 14.9 13.6 9.9 13.7 14.5 C-305-S 16.9 15.5 11.3 15.5 16.4 C-307-S

53

696

567

756

545

809

658

586

189

302

227

21.6 19.8 14.4 19.9 21.0

3

thru 5

3

thru 5

2

thru 5

3

thru 7-1/2

4

thru 10

C-414 11.5 10.5 7.6 10.5 11.1

C-414-S 12.4 11.4 8.3 11.4 12.1 C-415 15.8 14.5 10.6 14.6 15.4 C-415-S 17.5 16.1 11.8 16.2 17.1 C-417-S 22.1 20.3 14.8 20.4 21.5

C-419-S

67

936

713

1017

733

1088

885

788

254

407

305

24.3 22.3 16.3 22.4 23.7

5

thru 10

5

thru 12

5

thru 10

5

thru 12

7-1/2 thru 15

C-607-S 29.1 26.6 19.5 26.8 28.4 C-609-S

106

1392

1134

1512

1090

1618

1316

1172

378

604

454 33.2 30.4 22.3 30.7 32.4

15

15

10

15

20

*The filtration area is equal to the core surface area plus the large internal surface available for depth filtration. †20 drops = 1 gram = 1cc. **Based on 86 F liquid line temperature and a refrigerant flow of 3.1 pounds per minute per ton of Refrigerant 134a; 2.9 pounds per minute per ton of Refrigerant 22; 3.9 pounds per minute per ton for Refrigerant 404A; 2.9 pounds per minute per ton for Refrigerant 407C; 2.8 pounds per minute per ton for Refrigerant 410A and 4.1 pounds per minute per ton for Refrigerant 507. Ratings in accordance to ARI Standard 710. NOTES: 1. R-12 water capacity values are approximately 15 percent greater than R-134a. R-502 water capacities are similar to R-404A and R-507. 2. The variation in flow ratings of filter-driers having the same size core and shell is caused by the difference in connection sizes used.

FILTER DRIERS

648

FILTER DRIERS SPORLAN CATCH-ALL SUCTION LINE FILTER DRIER RECOMMENDATIONSFOR CLEAN-UP AFTER BURNOUT AND NEW SYSTEMS

SYSTEM CAPACITY IN HORSEPOWER

Refrigerant 22 & 407C Refrigerant 12, 134a, 404A, 502 & 507

TYPE NUMBER

CONNECTIONS (in.)

ODF Solder

Number of Cores

CORE PART NO

LENGTH(in.)

SOLDERSOCKETDEPTH

(in.)

WIDTH(in.)

PermanentInstallationwith Cores

Temporary Installation Cores for Cleanup;

Filter Elements

after Cleanup

PermanentInstallationwith Cores

Temporary Installation Cores for Cleanup;

Filter Elements

after Cleanup

C-084-S-T-HH 1/2 5.44 0.50 2.62 1 1/2

C-164-S-T-HH 1/2 6.00 0.50

C-165-S-T-HH 5/8 6.31 0.62

C-166-S-T-HH 3/4 6.75 0.62

2

1

C-167-S-T-HH 7/8 6.93 0.75

3.00

C-305-S-T-HH 5/8 9.25 0.62

C-306-S-T-HH 3/4 9.65 0.62

3

C-307-S-T-HH 7/8 9.80 0.75

2

C-309-S-T-HH 1-1/8 9.75 0.96

3.00

C-417-S-T-HH 7/8 9.81 0.75

5

C-419-S-T-HH 1-1/8 9.75 0.96

3.50

3

C-437-S-T-HH 7/8 10.34 0.75

C-439-S-T-HH 1-1/8 10.74 0.96

7-1/2 4

C-4311-S-T-HH 1-3/8 10.94 1.00

C-4313-S-T-HH 1-5/8 10.94 1.06

4.75

10 5

C-607-S-T-HH 7/8 16.00 0.75

SE

ALE

D T

YP

E

C-609-S-T-HH 1-1/8 16.00 0.96

3.00

5

3

C-144-S-TT-HH 1/2 4.14 0.50 2 1

C-145-S-TT-HH 5/8 4.38 0.62

C-146-S-TT-HH 3/4 4.83 0.69

3

2

C-147-S-TT-HH 7/8 4.97 0.75

SE

ALE

D T

YP

E

CO

MP

AC

T S

TY

LE

C-149-S-TT-HH 1-1/8

Sealed Type Filter

Driers

Sealed Type Filter

Driers

4.93 0.96

4.44 5

Select these types on basis of

permanent installation

3

Select these types on basis of

permanent installation

C-30013-G 1-5/8

C-30017-G 2-1/8

3

C-40017-G 2-1/8

25

50

15

25

C-40021-G 2-5/8

C-40025-G 3-1/8

C-40029-G 3-5/8 RE

PLA

CE

AB

LE

CO

RE

TY

PE

*

C-40033-G 4-1/8

4

RC-10098-HH or

RC-10098

30

60

20

30

*See page for RSF shells.

CATCH-ALL SUCTION LINE FILTER DRIER SELECTION INSTRUCTIONS

Selection of the proper Catch-All Suction Line Filter Drier will depend upon the intended usage. Either the “Permanent Installation with Cores” or “Temporary Installation Cores for Cleanup; Filter Elements after Cleanup” column may be used. When the best possible system protection is desired, the “Permanent with Cores” column should be used for selection. These recommendations are made on the basis of a low pressure drop, and as a result the cores can be left in the shell for maximum drying and acid removal when the system returns to normal operation delivering its full rated capacity.

An alternate selection that is satisfactory and less

expensive is to install cores temporarily for cleanup, and then remove these cores and install filter elements after cleanup. Because of the larger system capacity, the pressure drop through the temporarily installed cores will be somewhat larger than normal, but still within the limits. After cleanup, the use of filter elements will assure a minimum pressure drop when the system is in normal operation. The low pressure drop through the filter elements assures maximum energy savings during normal operation. Cleanup of the system can be accomplished with either the standard core (RC-10098) or the charcoal core (RC-10098-HH).

SIGNIFICANCE OF THE PART NUMBER

The letters and numerals in the Catch-All part number each have a significance. The “C” indicates Catch-All, and “CW” indicates the High Water Capacity Catch-All. The FIRST TWO OR THREE DIGITS indicate cubic inches of desiccant. The LAST ONE OR TWO DIGITS indicate fitting size in eighths. For sealed models, a “-S” following the last digit indicates solder fittings, and NO LETTER indicates a flare fitting. Replaceable core models (C-420 and larger) only have solder connections and the “-S” is omitted.

Examples: C-083 is 8 cu. in. and 3/8 in. flare, C-309-S is 30 cu. in. and 1-1/8 in. solder, C-19213 is 192 cu. in. and 1-5/8 in. solder.

Other suffix letters indicate special qualities. For example:

“-T” indicates a pressure tap consisting of a Schrader type access valve on the inlet end of the Catch-All.

“-HH” indicates a charcoal style core for wax removal and cleanup after a hermetic motor burnout.

FILTER DRIERS

649

FILT

ER D

RIER

S REPLACEABLE CORES AND PLEATED FILTER ELEMENTS

Cores for replaceable core type filter-driers are molded with the same desiccants that are used in the popular sealed filter-driers.

Cores are individually packed in metal cans, fully activated and hermetically sealed against moisture and dirt.

Filter elements are dried and packed in individuals sealed metal cans. This method of packaging prevents the element from picking up moisture from the atmosphere

Each can contains a “triple gasket” consisting of a new end plate gasket, an end plate gasket for certain competitive filter-driers, and a core gasket where desired. See the specifications on Page * for the number of cores required for each type drier.

RC-4864 — Activated Core — Order as separate item —Fits types C-480 thru C-19200 Series Shells. This is the standard core suitable for most installations in the liquid or suction line.

RCW-48 — High Water Capacity Core — Order as separate item — Fits types C-480 thru C-19200 Series shell. Designed specially for use with POE lubricants. This core should be used on systems that have a ruptured water cooled condenser, or that have been exposed to the atmosphere, or for some reason have a high amount of moisture in the system.

RC-4864-HH— Activated Charcoal Core— Order as separate item — Fits types C-480 thru C-19200 Series Shells. This core should be used for wax removal, and for clean-up of systems that have had a hermetic motor burnout.

RPE-48-BD — Filter Element — Order as separate item — Fits types C-480 thru C-19200 Series Shells and Replaceable Suction Filter (RSF) Shells. This element should be used in RSF shells installed in the suction line to obtain the lowest possible pressure drop. In cleaning up a system after a hermetic motor burnout, cores should be used first. After clean-up, the filter element should be installed.

RC-10098 —Activated Core — Order as a separate item — Fits types C-30,000 and C-40,000 Series Shells. This is the standard core suitable for liquid and suction line applications.

RCW-100 — High Water Capacity Core — Order as separate item — Fits types C-30,000 and C-40,000 Series Shells. Designed specially for use with POE lubricants. This core should be used on systems that have a ruptured water cooled condenser, or that have been exposed to the atmosphere, or for some reason have a high amount of moisture in the system.

RC-10098-HH — Activated Charcoal Core — Order as separate item — Fits types C-30,000 and C-40,000 Series Shells. This core should be used for wax removal, and for clean-up of systems that have had a hermetic motor burnout.

RPE-100 — Filter Element — Order as separate item — Fits types C-30,000 and C-40,000 Series Shells. This filter element should be used in the suction line to obtain the lowest possible pressure drop after cores were used for system clean-up.

HH STYLE CATCH-ALL FOR WAX REMOVAL

U.S. PATENT NUMBER 3,407,617

Small amounts of wax are often a problem on low temperature systems. Even well engineered systems frequently contain minute quantities of wax which are sufficient to clog expansion valve screens or cause sticking of the valve. Sporlan has developed a special blend of desiccants including activated charcoal which removes small amounts of wax in the liquid line before this wax can cause trouble at the expansion valve. These Catch-All Filter Driers have been very successful in correcting trouble jobs in the field.

By installing HH Style Catch-All Filter Driers in the liquid line of all low temperature systems these wax problems can be entirely prevented. In addition to their wax removal ability, these filter driers will remove all of the other harmful contaminants that the standard filter driers remove.

The following Catch-All Filter Driers are available with the HH core to meet the needs of low temperature systems. For dimensions, refer to the specifications for standard filter driers or consult Bulletin 40-10.

PART NO. CONNECTIONS

(in.) PART NO. CONNECTIONS

(in.)

C-052-HH 1/4 SAE Flare C-303-HH 3/8 SAE Flare


C-083-HH 3/8 SAE Flare C-304-S-HH 1/2 ODF Solder


C-163-HH 3/8 SAE Flare C-305-S-HH 5/8 ODF Solder

C-163-S-HH 3/8 ODF Solder C-414-HH 1/2 SAE Flare


C-164-S-HH 1/2 ODF Solder C-417-S-HH 7/8 ODF Solder

C-165-HH 5/8 SAE Flare RC-4864-HH

C-165-S-HH 5/8 ODF Solder RC-10098-HH

Replaceable Core

FILTER DRIERS

650

FILTER DRIERS REVERSIBLE HEAT PUMP FILTER-DRIER

DESIGN BENEFITS

• A short overall length for easy installation.

• Drier operates in either flow direction with low pressure drop.

• Proven metal check valves used in construction — no synthetic materials.

• The Sporlan dependable molded core used for maximum filtration ability. When the flow direction reverses, dirt already collected remains in the filter-drier.

• A carefully engineered blend of desiccants for maximum water capacity and acid removal ability. The HPC-160-HH Series also has the HH style core with activated charcoal which offers maximum ability to remove oleoresin and other reactive chemical constituents in the oil.

• Same rugged construction as used in the Catch-All.

SPECIFICATIONS -FOR NEW INSTALLATIONS AND HFC SYSTEM USE

Flow CapacityTons at 1 psi

ΔP Water Capacity

Dimensions

Refrigerant

Liquid Capacity Ounces (Wt.)

@100°F

R-22 Drops at 60 ppm

R-410A Drops at 80 ppm*

Part No

Connection Size Inches

Selection Recommendations

Tons

OverallLengthInches

DiameterInches

R-22

R-410A

75°F 125°F 75°F 125°F R-22

R-410A

HPC-103 3/8 Flare 6.75

HPC-103-S 3/8 Solder 5.88 3.4

3.3

HPC-104 1/2 Flare 6.94

HPC-104-S 1/2 Solder

1 thru 5 6.00

3.00

4.5

4.4

215

176

171

105

12.2

10.6

FOR CLEAN-UP AFTER BURNOUT

Dimensions

Water Capacity Refrigerant 22

Drops at 60 ppm Part No

Connection Size

Inches

Selection Recommendations

Tons

OverallLengthInches

DiameterInches

Flow CapacityR-22 Tons at 1

psi ΔP

75°F

125°F

Liquid Capacity Ounces (Wt.) R-22 @ 100°F

HPC-163-HH 3/8 Flare 1 thru 5 7.78 3.00 3.7 93 81 14.5

HPC-163-S-HH 3/8 Solder 1 thru 5 6.92 3.00 3.7 93 81 14.5

HPC-164-HH 1/2 Flare 1 thru 5 7.95 3.00 4.0 93 81 14.5


HPC-165-HH 5/8 Flare 1 thru 5 8.28 3.00 4.9 93 81 14.5


UL and ULc Listed — Guide-SMGT-File No. SA-1756A & B. Core volume is 10 cubic inches for HPC-100 Series and 14 cubic inches for the HPC-160-HH Series. Core surface filtering area is 18 sq. in. for the HPC-100 Series and 26 sq. in. for the HPC-160-HH Series. HPC-100 Series are rated for 650 psig; HPC-160-HH have a 500 psig rating. *As of this printing, ARI has not established an EPD for R-410A.

FILTER DRIERS

651

FILT

ER D

RIER

S SUCTION FILTER WITH THE EXCLUSIVE BI-DIRECTIONAL FEATURE

DESIGN BENEFITS • Protects the compressor from dirt

• A relief device opens if the filter plugs

• Suitable for use with all brazing alloys

• Maximum corrosion resistance

• Full flow design for low pressure drop

• Complete line of sizes

Sporlan offers an exclusive concept in Suction Filter design — a filter which is Bi-directional. When flow is in one direction, the bypass relief feature is active. If the pressure drop across the element becomes excessive the bypass relief will open slightly to maintain sufficient gas flow and assure proper cooling of the hermetic motor.

When the Suction Filter is installed with flow in the opposite direction, the bypass relief feature is inactive and will never open, regardless of the increase in pressure drop. The “-T” in the part number indicates that these models are equipped with an access valve to permit pressure drop readings. The access valve will be operational provided the Suction Filters are installed with the bypass feature inactive.

SPECIFICATIONSTypes with bypass relief feature (Bi-directional Flow)

Part No Dimensions WITHOUT AccessValve

WITH Access Valve CONNECTIONS (in) FILTER AREA Sq In Overall Length Inches SOCKET DEPTH Inches SHELL DIAMETERInches

SF-283-F — 3/8 SAE Flare 28 8.78 — 3.00— SF-285-T 5/8 ODF Solder 28 8.34 0.62 3.00— SF-286-T 3/4 ODF Solder 28 8.79 0.69 3.00— SF-287-T 7/8 ODF Solder 28 8.93 0.75 3.00— SF-289-T 1-1/8 ODF Solder 28 9.51 0.91 3.00— SF-489-T 1-1/8 ODF Solder 48 12.42 0.91 3.00— SF-4811-T 1-3/8 ODF Solder 48 13.10 0.97 3.00— SF-4813-T 1-5/8 ODF Solder 48 13.44 1.09 3.00

Types without bypass relief feature (Single Flow Direction)Part No Dimensions

WITHOUT AccessValve

WITH Access Valve CONNECTIONS (in) FILTER AREA Sq In Overall Length Inches SOCKET DEPTH Inches SHELL DIAMETERInches

SF-114 — 1/2 ODF Solder 11 4.36 0.50 2.00SF-114-F — 1/2 ODF Flare 11 5.25 — 2.00SF-115 — 5/8 ODF Solder 11 4.60 0.62 2.00SF-115-F — 5/8 ODF Flare 11 5.56 — 2.00— SF-6417-T 2-1/8 ODF Solder 388 1094 1.24 4.75— SF-6421-T 2-5/8 ODF Solder 388 1094 1.38 4.75

SELECTION RECOMMENDATIONSPart No NOMINAL SYSTEM HORSEPOWER* Refrigerant

WITHOUT Access Valve WITH Access Valve CONNECTIONS (in) 12, 134a, 404A, 502, 507 22, 407CSF-114 — 1/2 ODF 1/2 1SF-114-F — 1/2 SAE 1/2 1SF-115 — 5/8 ODF 1 2SF-115-F — 5/8 SAE 1 2SF-283-F — 3/8 SAE 1/2 1— SF-285-T 5/8 ODF 1-1/2 4— SF-286-T 3/4 ODF 1-1/2 5— SF-287-T 7/8 ODF 3 7-1/2— SF-289-T 1-1/8 ODF 5 7-1/2— SF-489-T 1-1/8 ODF 5 10— SF-4811-T 1-3/8 ODF 5 12— SF-4813-T 1-5/8 ODF 7 15— SF-6417-T 2-1/8 ODF 20 55— SF-6421-T 2-5/8 ODF 30 60*Use R-502 horsepower recommendations for R-502A & B and R-508A. Use R-12 horsepower recommendations for R-501A & B and R-509A. Ratings are in accordance with ARI Standard 730.

FILTER DRIERS

652

FILTER DRIERS REPLACEMENT SUCTION FILTER

The Replaceable Suction Filter shell, used with RPE-48-BD pleated filter element, is designed to be installed in the suction line of new systems to remove resident contaminants.

DESIGN BENEFITS:

• Low pressure drop

• Can be used with desiccant cores for clean-up after burnout

• Various fitting sizes up to 3-1/89line size

• Access valve supplied for pressure drop measurement or charging

HOW IT’S USED – Sporlan Replaceable Suction Filters are installed in the suction line of air conditioning systems to remove contaminants that may be in the system at start-up. The Replaceable Suction Filter has large fittings permitting the use of a small shell on a system with a large line size, resulting in considerable economy. The angle construction is suitable for flow in either direction, which results in easy installation even on compact racks. The Replaceable Suction Filters should be used with cores for cleaning up a system after a hermetic motor burnout. Select the RC-4864, RC-4864-HH or RCW-48 replaceable cores. After clean-up, install RPE-48-D elements in the shells.

SELECTION – The table below gives information for choosing the proper model for a given system. The filter elements are supplied in hermetically sealed metal cans.

SELECTION RECOMMENDATIONS WITH FILTER ELEMENTSNOMINAL SYSTEM HORSEPOWER

Refrigerant

PART NO

CONNECTIONS Inches

ODF Solder 12 & 134a 22 & 407C 404A, 502 & 507

NO. OF FILTER

ELEMENTS

NO. OF CORES

OVERALL LENGTH Inches

RSF-487-T 7/8 7 10 10 9.30 RSF-489-T 1-1/8 8 15 12 9.37

RSF-4811-T 1-3/8 10 20 15 9.60 RSF-4813-T 1-5/8 12 25 20 9.60 RSF-4817-T 2-1/8 20 35 25 9.37 RSF-4821-T 2-5/8 25 50 35

One

RPE-48-BD

One

RC-4864 or

RC-4864-HH

9.75 RSF-9617-T 2-1/8 20 40 30 14.96 RSF-9621-T 2-5/8 30 50 40 15.43 RSF-9625-T 3-1/8 40 80 55

Two RPE-48-BD

Two RC-4864

or RC-4864-HH 15.12

Safety screen Part No.: 6171-S is required when cores are used in the RSF shell. Remove the screen when RPE-48-BD elements are used. UL and ULc Listed — Guide-SMGT-File No. SA-1756A & B.

ACID TEST KIT

PART NO TA-1 One Time Acid Test Kit

FILTER DRIERS

653

MOIS

TURE

AND

LIQ

UID

INDI

CATO

RS

See -All Moisture and Liquid Indicators offers these 8 outstanding benefits

1. The See•All Moisture and Liquid Indicator provides a true moisture indication for Refrigerants 12, 134a, 22, 404A, 407C, 410A, 502 and 507. The See All is also suitable for Refrigerants 401A & B, 402A & B, 408A and 409A. The dark green indicates dry and a bright yellow indicates wet. The one indicator avoids the confusion found in models with two elements. You cannot pick the wrong element when checking the moisture content of the system.

2. RELIABLE and ACCURATELY CALIBRATED COLOR CHANGE POINTS. The See•All Moisture and Liquid Indicator is accurately calibrated in parts per million of moisture for each refrigerant. All moisture indicators change color on the basis of relative saturation of the refrigerant. Therefore, liquid line temperature must be considered if an accurate calibration is to be obtained. A color chart is part of the label, for easy comparison.

3. COLOR CHANGES ARE EASILY DISTINGUISHED and REVERSIBLE. The indicator’s color differs so widely between WET and DRY conditions that there is no possibility of confusion between the two. Colors will reverse as often as moisture concentration in the system changes.

4. LARGE FULL VIEW SIGHT GLASS. The See•All Moisture and Liquid Indicator has an extra large crystal clear sight glass for viewing the refrigerant. Bubbles indicate a shortage of refrigerant or a restriction in the liquid line.

5. INDICATOR PROTECTED from DISCOLORATION and DIRT. The indicator is protected by a filter pad and screen. This prevents washing of the indicator by the refrigerant and protects it from system contamination and turbulence.

6. REPLACEABLE INDICATOR ELEMENT. The color indicator paper can be changed on the new fused glass models without removing the See•All from the line. Replacement is thru the bottom (see SA-14SU below). Request the K-SA-4 kit.

7. DISASSEMBLY OF THE SMALLER SIZES NOT REQUIRED.The extended steel fittings on solder models in the smaller sizes make it unnecessary to disassemble for installation since steel conducts onl one eighth as much heat as copper.

8. A DOUBLE DUTY PLASTIC CAP is supplied to keep the glass free from dust, dirt, and grease. It also permits the service engineer to use his own discretion concerning instructions to his customers on observing the See•All Moisture and Liquid Indicator.

Specifications

MALE FLARE FEMALE & MALE

FLARE MALE FLARE X

SWIVEL NUT SWIVEL NUT X SWIVEL NUT

FEMALE FLARE X SWIVEL NUT

SWIVEL NUT X ODF SOLDER

ODF SOLDER CONNEC -TION SIZES Inches

Part No

Overall Length Inches

Part No


Part No


Part No


Part No


Part No


Part No


1/4 SA-12 2.87 SA-12FM 2.56 — — — — — — — — SA-12S

3/8 SA-13 3.37 SA-13FM 2.97 SA-13U 3.64 SA-13UU 3.95 SA-13UU 3.19 SA-13SU 4.19 SA-13S 4.62

1/2 SA-14 3.81 SA-14FM 3.44 SA-14U 4.13 SA-14UU 4.50 SA-14UU 3.75 SA-14SU 4.62 SA-14S

5/8 SA-15 4.13 — — SA-15U 4.44 SA-15UU 4.75 — — SA-15SU 4.89 SA-15S 4.87

7/8 — — — — — — — — — — — — SA-17S

1-1/8 — — — — — — — — — — — — SA-19S 6.31

1-3/8 — — — — — — — — — — — — SA-211

1-5/8 — — — — — — — — — — — — SA-213

2-1/8 — — — — — — — — — — — — SA-217

7.97

Listed by Underwriters’ Laboratories, Inc. - Guide SEYW - File No. SA3182 Maximum Rated Pressure – 650 psi. Overall width is: 1.31 in. for 1/4 in. and 3/8 in. sizes, 1.58 in. for 1/2 in. and 5/8 in. sizes, and 1.38 in. for 7/8 in. and 1-1/8 in. sizes. Most solder connections can be used as male fittings as well as female fittings. The 1/4 in. ODF is 3/8 in. ODM, the 3/8 in. ODF is 1/2 in. ODM, the 1/2 in. ODF is 5/8 in. ODM, and the 5/8 in. ODF is 3/4 in. ODM. Models with female flare and/or swivel nut connections are supplied with a copper gasket in the fitting.

Moisture Content PPM

REFRIGERANT 12 22 134a 502 404A & 507 407C 410A SEE•ALL

SHOWS

LIQUID LINE TEMP 75° F 100° F 75° F 100° F 75° F 100° F 75° F 100° F 75° F 100° F 75° F 75° F

Green Dry Below 5 Below 10 Below 30 Below 45 Below 50 Below 80 Below 10 Below 20 Below 15 Below 30 Below 120 Below 75Chartreuse CAUTION 5-15 10-30 30-90 45-130 50-200 80-225 10-45 20-65 15-90 30-140 120-280 75-150

Yellow WET Above 15

Above 30

Above 90

Above 130

Above 200

Above 225

Above 45

Above 65

Above 90

Above 140

Above 280

Above 150

NOTE: Change or add Catch-All Filter-Drier when paper turns from green to chartreuse.

MOISTURE AND LIQUID INDICATORS

654

DISCHARGE BYPASS VALVES SPORLAN DISCHARGE BYPASS VALVES

The Sporlan line of discharge bypass valves are designed to provide an economical method of compressor capacity control in place of cylinder Unloader or to handle unloading requirements below the last step of cylinder unloading. These modulating control valves automatically bypass the required amount of discharge gas to the low side to maintain the desired minimum evaporator pressure. The valves are applicable on any refrigeration or air conditioning system that operates during periods of low load, which can result in coil icing or short cycling. These valves respond to downstream pressure changes and open when the evaporator pressure falls below the valve setting. At normal loads and evaporator conditions, the valve remains closed and the system operates in a conventional manner.

The DR line of valves consists of three basic types of valves: the adjustable models, the adjustable remote bulb models, andthe non-adjustable models.

The SHGB valves are adjustable and pilot operated with a solenoid stop feature that eliminates the need for a hot gas solenoid valve. They were developed for use on larger capacity systems.

APPLICATION — The discharge bypass valve is normally applied in a branch line off the discharge line. To allow system pump down control, a solenoid valve or hand valve must be installed upstream of the discharge DR type bypass valves. The bypassed hot gas can enter the low side at several locations; however, two of the possible locations are preferred because of superior operating performance: into the side connection of a Sporlan side connection distributor or directly into the suction line. By using the side connection distributor method, the system TEV will act as a desuperheating valve to keep the compressor suction temperature below the recommended maximum temperature published by the compressor manufacturer. When the hot gas is bypassed directly into the suction line, an auxiliary desuperheating TEV may be required.

SELECTION and CAPACITY RATINGS —The capacities given in the table below are valve hot gas capacities and not the capacities of the system on which the valve is to be applied. To select a valve, first determine the compressor capacity at the minimum allowable evaporating temperature.

Then the discharge bypass valve must supply the difference between this compressor capacity and the minimum evaporator load at which the system is to be operated. The valve pressure setting will be that pressure at which the bypass valve must start to open.

Connections – (Standard Connections are in BOLD type). ADRS(E)-2 – 3/8 in., 1/2 in., 5/8 in. ODF Solder or 3/8 in., 1/2 in., 5/8 in. SAE Flare ADRP(E)-3 – 1/2 in., 5/8 in. ODF Solder on 1/2 in., 5/8 in. SAE Flare ADRHE-6 & DRHE-6 – 5/8 in., 7/8 in., 1-1/8 in. ODF Solder SHGB(E)-8 – 7/8 in. ODF, 1-1/8 in. ODF Solder SHGB(E)-15 – 1-1/8 in., 1-3/8 in. ODF Solder

Valves with ODF solder connections are supplied standard with 1/4 in. ODF external equalizer, 1/4 in. SAE Flare external equalizer available on special order. Pilot operated models are supplied with 1/4 in. SAE external equalizer.

DISCHARGE BYPASS VALVES

655

DISC

HARG

E BY

PASS

VAL

VES

SPORLAN DISCHARGE BYPASS VALVESDISCHARGE BYPASS VALVE CAPACITIES — Tons

Capacities based on 6° F evaporator temperature change from closed to rated opening (does not apply to pilot operated models), discharge temperature 30° F above isentropic compression, 100° F condensing temperature, 0° F subcooling, 25° F superheat at the compressor and includes both the hot gas bypassed and liquid refrigerant for desuperheating, regardless of whether the liquid is fed through the system thermostatic expansion valve or auxiliary desuperheating thermostatic expansion valve.

VALVE TYPE & ADJUSTMENT RANGE (psig) ADRI-1-1/4

ADRIE-1-1/4 ADRS-2

ADRSE-2 ADRP-3

ADRPE-3

ADRHE-6 DRHE-6

(Adjustable “Remote Bulb” Model)*SHGB-8

SHGBE-8SHGB-15

SHGBE-15

REFRIGERANT

MINIMUM ALLOWABLE

EVAPORATOR TEMPERATURE 0/55 0/75 0/100 0/30 0/80 0/30 0/80 0/30 0/80 25/35 32/44 55/70 65/80 0/100 0/75

40 — 0.58 0.53 — 3.51 — 5.99 — 9.16 — — 1 9.8 — 15.7 58 26 0.44 0.64 0.54 — 3.57 — 6.26 — 9.90 — — 1 6.9 — 15.9 62 0 0.63 0.60 0.49 3.90 3.66 7.38 6.61 13.9 10.9 — — — — 16.2 66

22

–20 0.59 0.50 0.44 3.75 3.65 7.45 6.64 14.1 11.0 — — — — 16.2 69 40 0.40 0.43 0.34 — 2.67 — 4.94 — 9.34 9.64 — — — 10.9 41 26 0.41 0.39 0.32 2.60 2.44 4.95 4.42 9.36 7.26 8.31 — — — 10.9 43

134a

0 0.38 0.31 0.28 2.46 — 4.89 — 9.41 — — — — — 11.0 46 40 0.45 0.48 0.39 — 2.76 — 4.95 — 7.99 — 11.0 — — 12.3 52 26 0.47 0.45 0.37 2.97 2.79 5.66 5.04 10.7 8.26 — 9.49 — — 1 .4 52

401A

0 0.44 0.36 0.32 2.83 2.74 5.62 5.01 10.8 8.32 — — — — 12.5 56 40 — — 0.54 — — — — — — — — — — 17.3 — 26 — 0.65 0.60 — 3.91 — 6.66 — 10.3 — — — — 17.7 63 0 0.66 0.72 0.57 — 4.00 — 7.16 — 11.7 — — — — 17.9 63

402A

–20 0.69 0.63 0.52 4.22 4.04 8.11 7.33 15.3 12.2 — — — — 18.0 64 40 — — 0.55 — — — — — — — — — — 17.5 — 26 — 0.67 0.60 — 3.91 — 6.70 — 10.4 — — — 21.4 17.7 64 0 0.67 0.71 0.56 — 4.00 — 7.16 — 11.7 — — — — 17.9 65

404A

–20 0.68 0.61 0.51 4.17 4.02 8.08 7.28 15.3 12.1 — — — — 17.9 65 40 — 0.78 0.65 — 4.25 — 7.50 — 12.1 — — 22.9 — 18.6 74 26 0.61 0.78 0.63 — 4.25 — 7.50 — 12.1 — 19.3 — — 18.7 75 0 0.74 0.68 0.56 4.51 4.31 8.63 7.81 16.3 13.0 — — — — 18.9 76

407C

–20 0.68 0.56 0.50 4.33 4.23 8.64 7.71 16.5 12.9 — — — — 19.1 77 40 — — 0.46 — 3.14 — 5.28 — 7.85 — — — 19.2 14.3 — 26 — 0.56 0.49 — 3.19 — 5.51 — 8.55 — — — 16.6 14.5 55 0 0.55 0.57 0.46 3.58 3.28 6.64 5.90 12.5 9.62 — — — — 14.7 59

502

–20 0.55 0.59 0.41 3.43 3.30 6.68 6.00 12.6 9.91 — — — — 14.8 61 40 — — 0.53 — — — — — — — — — — 17.4 — 26 — 0.65 0.59 — 3.87 — 6.60 — 10.2 — — — — 17.7 64 0 — 0.71 0.57 — 3.96 — 7.09 — 11.5 — — — — 17.8 64

507

–20 0.69 0.62 0.52 4.17 4.00 8.02 7.25 15.2 12.0 — — — — 17.9 65

PART NO DESCRIPTION

ADRS-20/30ODF ADRS-2 0/30 4 ODF


ADRSE-20/304ODF ADRSE-20/304ODF







ADRP-30/304ODF ADRP-3 0/30 4 ODF


ADRPE-30/304ODF ADRPE-30/304ODF






ADRHE-60/305ODF ADRHE-60/305ODF

PART NO DESCRIPTION

ADRHE-60/805ODF ADRHE-6 0/80 5 ODF



DRHE-6-55/70AR7X7 DRHE-6-55/70AR 7 ODF

DRHE-6-55/70AR9X9 DRHE-6-55/70AR 9 ODF

SHGBE-8-0/1009ODF SHGBE-8-0/100 9 ODF LESS COIL


SHGB-8-0/107ODF SHGB-8-0/100 7 ODF LESS COIL





SHGBE-15-0/7511 ODF SHGBE-15-0/75 11 ODF LESS COIL

DISCHARGE BYPASS VALVES

656

PRESSURE REGULATING VALVES CRANKCASE PRESSURE REGULATING VALVES

Crankcase Pressure Regulating Valves are designed to prevent overloading of the compressor motor by limiting the crankcase pressure to a predetermined maximum value during and after a defrost cycle or a normal shutdown period. These valves automatically throttle the vapor flow from the evaporator until the compressor can handle the load.

Sporlan manufactures five adjustable models… CRO-4, CRO-6, CROT-6, CRO-10 and CROT-10…all models respond only to their outlet pressure and modulate to prevent the suction pressure at the compressor from rising above the valve setting. Since these valves are adjustable, the setting may be altered to suit the specific system requirements. SELECTION and CAPACITY RATINGS

The ratings for these valves vary depending on three items: design suction pressure after pull down, maximum allowable suction pressure recommended by the compressor or unit manufacturer (this is the valve setting), and pressure drop across the valve. The difference between the design suction pressure and the valve setting determines how much of the valve stroke is used. Therefore, the valve setting should be kept as high as possible without exceeding the recommendation of the compressor or unit manufacturer.

PART NO* SPORLAN MODEL

CRO-4-0/20 4X4 ODF LS

CROT-10 30/110 9 ODF WS

CROT-10 30/110 11 ODF WS

CROT-10 0/6011ODF WS

CROT-10 0/60 1-1/8"ODF

CROT-10 0/60 7 ODF WS

CROT-10 30/110 7 ODF WS

CROT-12-65/225 9 ODF

CROT-15-65/225 11 ODF


CROT-6 0/60 1/2" SAE

CROT-6 0/60 5/8" SAE





HEAD PRESSURE CONTROL VALVES

Sporlan Head Pressure Control for systems with air cooled condensers can be accomplished with several valve types or combinations. The valve types are: LAC-4, OROA-5, LAC-5, LAC-10, ORI/ORD combination and the ORIT/CROT combination.

The LAC, OROA, ORI and ORIT are designed for application in the liquid line and should not be applied in the discharge line for any reason. Compressor pulsations can greatly shorten the life of the valves. If any of the valves are applied in any manner other than described here, the Sporlan warranty is void.


ORD-4-20 5/8 ODF

ORD-4-20 7/8 ODF

ORD-4-25 5/8 ODF

ORD-4-30 5/8 ODF

ORD-4-35 5/8 ODF

ORI-10 65/225 1-1/8"

ORI-10 65/225 1-3/8"

ORI-10 65/225H 7ODF WS

ORI-10 65/225H 11 ODF WS

ORI-6 65/225 5/8" WS

ORI-6 0/50 5 ODF WS

ORI-6 65/225 7/8" WS

ORI-6 65/225H 9ODF WS

ORIT-15-65/225 11 ODF

ORIT-20-65/225 13 ODF


OROA-5-100 5/8 ODF WS






IMPORTANT NOTES: WS - With Strainer LS - Less Strainer


LAC-10-100 11X7 ODF LS

LAC-10-100 11X9 ODF LS

LAC-4-100 1/2 ODF LS

LAC-4-180 3/8 0DF LS




LAC-5-100 1-1/8 ODF LS

LAC-5-210 5/8 ODF WS

LAC-5-75 1/2 ODF LS


CROT-12-65/225 9 ODF

CROT-15-65/225 11ODF


PRESSURE REGULATING VALVES

657

PRES

SURE

REG

ULAT

ING

VALV

ES

DEFROST DIFFERENTIAL PRESSURE REGULATING VALVESADJUSTMENT RANGE AND PRESSURESETTINGS

All defrost differential valves are set by turning the adjusting stem located under the cap on the pilot differential valve. The adjustment range is 5 to 50 psig. The (O)LDR has a factory setting of 18 psid and the DDR-20 has a factory setting of 30 psid. Turning the stem clockwise increases the setting, counterclockwise decreases the setting.

DDR-20 VALVE OPERATION

The DDR-20 is designed to create a differential pressure between its inlet (discharge) pressure and the receiver pressure. A solenoid bypass feature is incorporated in the valve so that the valve can be made to go full open when there is no need for a differential to be created. Energizing the solenoid coil opens the valve fully. LOCATION

The (O)LDR valve is located between the receiver and the liquid header. The DDR-20 is located in the discharge line before the condenser.


OLDR-15 11ODF LESS COIL




DDR-20 13 ODF LESS COIL


EVAPORATOR PRESSURE REGULATING VALVES The Sporlan line of evaporator pressure regulating (EPR) valves are designed to provide an accurate and economical means of balancing system capacity and load requirements during “low” loads and/or while maintaining different evaporator conditions on multi-temperature evaporator systems. These valves control evaporator temperature by maintaining evaporator pressure. As the evaporator load increases the ORI valves will Open on Rise of I nlet pressure above the valve’s setting to provide more flow capacity to meet the evaporator load. When the evaporator load decreases the valves will modulate closed to maintain the pressure setting of the valve. Sporlan offers a number of EPR valve types in various sizes, and with optional features to accommodate almost any industry requirement. For more complete information on any of the EPR valve types see your Sporlan Wholesaler or contact your Sporlan Sales Engineer. APPLICATIONS

• Maintain minimum evaporator temperature to avoid frost on air coils and provide improved humidity control

• Evaporator temperature control for food merchandisers (single and multiple evaporator systems)

• Evaporator temperature control on water chilling units

PART NO*

SPORLAN MODEL PART NO*

SPORLAN MODEL

ORI-6 0/50 5 ODF WS SORIT-12 0/100 208-240VAC 9ODF

ORIT-10 0/50 7 ODF WS SORIT-12-0/100 LC 9ODF



ORIT-10 30/100 7 ODF WS SORIT-PI-211S-0/100 LC

ORIT-10 30/100 9 ODF WS SORIT-PI-25S-0/100 LESS COIL

ORIT-10 30/100 11 ODF WS SORIT-PI-25SE-0/100 LESS COIL

ORIT-12 0/100 9 ODF SORIT-PI-27S-0/100 LESS COIL

ORIT-15 0/100 11 ODF SORIT-PI-27SE-0/100 LESS COIL

ORIT-20 0/100 13 ODF SORIT-PI-29S-0/100 LESS COIL

ORIT-6 0/50 5/8" SAE SORIT-PI-29SE-0/100 LESS COIL

ORIT-6 0/50 1/2" SAE SORIT-PI-311S-0/100 LESS COIL





ORIT-PI-25-0/100 SORIT-PI-413S-0/100 LESS COIL






ORIT-PI-413-0/100

ORIT-PI-513-0/100 IMPORTANT NOTES:WS - With Strainer

*( ) Please contact your local Carlyle Certified Refrigeration Partner or RCD

Customer Service for P/N and Pricing.

PRESSURE REGULATING VALVES

658

ELECTRONIC TEMP CONTROL SYSTEMS/OIL FILTERS ELECTRONIC TEMPERATURE CONTROL SYSTEMS

Type CDS-9 and CDS-16


CDS-16 11ODF 10'-S ST

CDS-16 11ODF 20'-S ST

CDS-9 7ODF 20'-H

CDS-9 9ODF 20'-S


SERIES OIL FILTERDESIGN BENEFITS

• Virtually eliminates the need for oil changes due to suspended particulate in circulation

• Unsurpassed filtering efficiency 99% removal of 3 micron sized particles 98% removal of 2 micron sized particles

• Element utilizes a pleated design for maximum surface area

• Unsurpassed filtration capacities ESIGN BENEFITS

• High flow capacities with low pressure drop

• Filter element utilizes an O-ring seal

• Inert micro glass filter material insures lubricant compatibility

• Dimensions allow for easy replacement of current filter

The Sporlan Catch-All or SF-283-F Suction Filter has been used for many years as an oil filter in refrigeration rack systems with mineral or alkylbenzene as the lubricant of choice.

With the use of the new polyolester (POE) oils, system chemistry has changed. Unlike mineral and alkylbenzene oils, POE oil has solvent like tendencies. POE oil has the ability to suspend and recirculate small, solid contaminants left from system installation or retrofit. Analysis of POE oil samples taken from actual systems have shown the oil to suspend and recirculate a high concentration of 2-20 micron sized particles, with the largest percentage between 2-10 microns. Although some particles are smaller than bearing tolerances, studies have shown bearing life can still be affected.

Bearing wear depends upon the size, hardness, and concentration of particles in circulation. To effectively remove these small particles, Sporlan developed a new type of oil filter.

The OF Series Oil Filters are designed to be 99% efficient in removing 3 micron sized particles and yet have sufficient flow capacity at a low pressure drop. The unsurpassed filtration ability of the oil filters will assure clean POE, mineral, or alkylbenzene oil is returned to the compressors. Clean oil insures proper operation of the oil level control and minimizes compressor wear. The Sporlan OF Series Oil Filters were designed to virtually eliminate the need for oil changes resulting from suspended solid contaminants in circulation.


OF-303 OIL FILTER

OF-303-T OIL FILTER

OF-303-BP OIL FILTER

ROF-413-T REPLACEABLE FILTER

OFE-1 OIL FILTER ELEMENT


ELECTRONIC TEMP CONTROL SYSTEMS/OIL FILTERS

659

OIL

LEVE

L CO

NTRO

L SY

STEM

OIL LEVEL CONTROL SYSTEM

The OCV will only relieve pressure from the reservoir in excess of its fixed set point. Systems with fluctuating suction pressure as a result of compressor unlades, staging or other suction line controls must be fitted with an OCV with a differential greater than the suction pressure fluctuation to assure oil flow from the OR-1-1/2 through the oil level control to the compressor crankcase.

Sporlan offers OCV’s with a 5, 10, and 20 psi fixed differential setting. However, Sporlan recommends the use of an OCV-20 on all field built up applications.

OIL LEVEL CONTROLS

The purpose of the Sporlan Oil Level Control is to regulate the flow of oil to the compressor crankcase to maintain a minimum oil level as specified by the compressor manufacturer for any given application.

Sporran’s Oil Level Control System Components were developed to offer the refrigeration industry an oil level control system of the highest quality. The heart of the system is the Oil Level Control which when matched with the Oil Reservoir and Oil Differential Check Valve maintains a minimum oil level in the compressor crankcase during all phases of system operation.

OIL RESERVOIR Type OR-1-1/2

The Sporlan Oil Reservoir (OR-1-1/2) is a holding vessel to contain the oil that is not within the crankcase, the oil separator, or in circulation. The OR-1-1/2 has an inlet and an outlet service valve so it may be isolated from the rest of the system, or the oil supply from the oil reservoir to the Oil Level Control can be eliminated for service. The OR-1-1/2 also contains two sight glasses so the maximum and minimum oil level can be observed. The sight glasses are placed on the shell symmetrically so 1/4 gallon of oil is contained between the lower sight glass and the bottom of the shell; 1 gallon is contained between the sight glasses; and 1/4 gallon is contained between the upper sight glass and the top of the shell. This allows the shell to be mounted vertically with either service valve on top. Depending on which end of the OR-1-1/2 Oil Reservoir is mounted to the top, the oil service valves will be pointing either right or left for piping convenience.

OIL DIFFERENTIAL CHECK VALVE Types OCV-5, OCV-10, OCV-20

The Sporlan Oil Level Differential Check Valve (OCV) is installed on the 3/8 SAE fitting on top of the OR-1-1/2, and allows pressure to be relieved from the reservoir to the suction as required to maintain a pressure in the reservoir at a preset level above the suction pressure. The pressure differential created by the OCV assures oil flow from the reservoir to the Oil Level Control providing there is adequate oil in the reservoir. NOTE: OL-60CH replaces OL-1CH and OL-2CH; OL-60FH replaces OL-1FH and OL-2FH models.


OL-60CH OIL LEVEL CONTROL

OL-60FH OIL LEVEL CONTROL

OL-60XH OIL LEVEL CONTROL

OR-1-1/2 OIL RESERVOIR

OCV-10 CHECK VALVE

OCV-20 CHECK VALVE

OCV-30 CHECK VALVE

OCV-5 CHECK VALVE

S-OL OIL LEVEL SIGHT GLASS KIT

AOL-A COPELAND ADAPTOR

AOL-K-1 ADAPTOR KIT -OM-1

AOL-R-1 KIT


TEMPERATURE RESPONSIVE MISCELLANEOUS VALVES, REPLACEMENT PARTS, PARTS KITS, SOLENOID COILS, AND STRAINER

PART NO*

SPORLAN MODEL

ADRHE-60/307 ODF

ADRHE-60/309 ODF

ADRIE-1-1/4-0/55 3X3 ODF ST


825-005 INLET STRAINER 5/8 ODF


825-009 INLET STR 1-1/8 ODF




6034 Y-TYPE 1/2 FPT STRAINER

PART NO*

SPORLAN MODEL

K-PI-E KIT

RK-SORIT-PI-2 0/100

RK-SORIT-PI-3 0/100

RK-SORIT-PI-4 0/100

KS-12DB

KS-12DC

KS-16DB

KS-ORI/CDA-15 INT PARTS KIT


K-SORIT-PI KIT

K-Y1005-1 0/100 PILOT ASSY KIT

OMKC-2 120/50-60 JAM

OMKC-2 208-240/50-60 JAN

PART NO*

SPORLAN MODEL

Y 1037-FV-1-1/2-190 3VX3 ODF 5’

Y 1037-FV-1-190 3VX3 ODF 30’

Y 1037-FV-2-190 3VX3 ODF 5’

Y 1037-FV-3-190 3VX3 ODF 5’

Y 1037-FV-5-190 3VX3 ODF 5’

Y 1037-FV-1/2-190 3VX3 ODF 5’

Y 1037-FV-1/2-220 3VX3 ODF 5’

Y 1037-FV-1/2-230 3VX3 ODF 5’

Y 1037-FV-1/2-250 3VX3 ODF 5’

Y 1037-FV-1/3-190 3VX3 ODF 5’

Y 1037-FV-1-1/2-220 3VX3 ODF 5’

Y 1037-FV-1-1/2-230 3VX3 ODF 5’

Y 1037-FV-1-1/2-250 3VX3 ODF 5’

Y 1037-FV-1-220 3VX3 ODF 5’

Y 1037-FV-1-230 3VX3 ODF 5’

Y 1037-FV-1-250 3VX3 ODF 5’

* ( ) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.

OIL LEVEL CONTROL SYSTEM

660

MISCELLANEOUS

PART NO*

SPORLAN MODEL

ADRHE-60/307 ODF

ADRHE-60/309 ODF









PART NO*

SPORLAN MODEL

K-PI-E KIT

RK-SORIT-PI-2 0/100

RK-SORIT-PI-3 0/100

RK-SORIT-PI-4 0/100

KS-12DB

KS-12DC

KS-16DB



K-SORIT-PI KIT

K-Y1005-1 0/100 PILOT ASSY KIT

PART NO*

SPORLAN MODEL

MKC-1 120/50-60 JAM

MKC-1 208-240/50-60 JAN

MKC-1 24/50-60 JAQ

MKC-1-DUAL/50-60 JAU

MKC-2 24/50-60 JAQ

MKC-2 120/50-60 JAM

MKC-2 208-240/50-60 JAN

MKC-2-DUAL/50-60 JAU

OMKC-2 120/50-60 JAM

OMKC-2 208-240/50-60 JAN

6034 Y-TYPE 1/2 FPT STRAINER

* ( ) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.

MISCELLANEOUS

661

Issue Date : 2011-09-30 Z - Variable Frequency Drives

Variable Frequency Drives

As variable frequency drives (VFDs) from multiple manufacturers are used in Seresco Technologies Inc.'s

products, please ensure that you are aware which model is used in your unit before consulting this guide.

Siemens MicroMaster VFDs

WARNING This equipment contains dangerous voltages and controls potentially dangerous

rotating mechanical parts. Non-compliance with Warnings failure to follow the instructions contained in

this manual can result in loss of life, severe personal injury or serious damage to property. Only suitable

qualified personnel should work on this equipment, and only after becoming familiar with all safety

notices, installation, operation and maintenance procedures contained in this manual. The successful and

safe operation of this equipment is dependent upon its proper handling, installation, operation and

maintenance.

WARNING The DC link of all MICROMASTER modules remains at a hazardous voltage level

for 5 minutes after all voltages have been disconnected. Therefore always wait for 5 minutes after

disconnecting the inverter from the power supply before carrying out work on any modules. The drive unit

discharges itself during this time.

This equipment is capable of providing internal motor overload protection in accordance with UL508C section

42. Refer to P0610 (level 3) and P0335. Motor overload protection can also be provided using an external PTC

via a digital input. This equipment is suitable for use in a circuit capable of delivering not more than 10,000

symmetrical amperes (rms), for a maximum voltage of 230/460 V when protected by an H or K type fuse, a

circuit breaker or self-protected combination motor controller controller (for more details see Operating

Instructions Appendix F). Use Class 1 60/75 °C copper wire only with the cross-sections as specified in the

Operating Instructions.

Before installing and commissioning, please read these safety instructions and warnings carefully and all the

warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and

replace missing or damaged labels.

Table 1. Maximum permissible ambient temperature

Frame Sizes A-F50 °C at constant torque (CT) and 100 %

40 °C at variable torque (VT) and 100 %

1

Z - Variable Frequency Drives Issue Date : 2011-09-20

Frame Sizes FX and GX 40 °C at 100 % permissible output current

MM420 MM440

Figure 1. MM420 Block Diagram Figure 2. MM440 Block Diagram

Figure 3. MM420 LED Status Display Figure 4. MM440 LED Status Display

2


Table 2. Fault Messages

MM420 MM440

Fault Significance Fault Significance

F0001 Overcurrent

F0002 Overvoltage F0002 Overvoltage

F0003 Undervoltage F0003 Undervoltage

F0004 Inverter Overtemperature F0004 Inverter Overtemperature

F0005 Inverter I2t F0005 Inverter I2t

F0011 Motor Overtemperature I2t F0011 Motor Overtemperature I2t

F0012 Inverter temp. Signal lost

F0015 Motor temp. Signal lost

F0010 Mains Phase Missing

F0021 Earth Fault

F0022 HW Monitoring Active

F0023 Output Fault

F0024 Rectifier Overtemperature

F0030 Fan Has Failed

F0035 Auto Restart after n

F0040 Automatic Calibration Failure

F0041 Stator resistance measurement failure F0041 Motor Data Identification Failure

F0042 Speed Control Optimization Failure

F0051 Parameter EEPROM Fault F0051 Parameter EEPROM Fault

F0052 Powerstack Fault F0052 Powerstack Fault

F0053 IO EEPROM Fault

F0054 Wrong IO Board

F0060 Asic Timeout F0060 Asic Timeout

F0070 Communications board setpoint error F0070 Communications board setpoint error

F0071 No Data for USS (RS232 link) during Telegram Off Time F0071 USS (BOP Link) setpoint fault

F0072 No Data from USS (RS485 link) during Telegram Off Time F0072 USS (COM Link) setpoint fault

F0080 Analogue input - lost input signal F0080 Analogue input - lost input signal

F0085 External Fault F0085 External Fault

F0090 Encoder Feedback Loss

F0101 Stack Overflow F0101 Stack Overflow

F0221 PI Feedback below minimum value F0221 PI Feedback below minimum value

F0222 PI Feedback above maximum value F0222 PI Feedback above maximum value

F0450 BIST Tests Failure F0450 BIST Tests Failure

F0452 Belt Failure Detected

3


Table 3. Alarm Messages

MM420 MM440

Alarms Significance Alarms Significance

A0501 Current Limit A0501 Current Limit

A0502 Overvoltage limit A0502 Overvoltage limit

A0503 Undervoltage Limit A0503 Undervoltage Limit

A0504 Inverter Overtemperature A0504 Inverter Overtemperature

A0505 Inverter I2t A0505 Inverter I2t

A0506 Inverter Duty Cycle A0506 Inverter Duty Cycle

A0511 Motor Overtemperature I2t A0511 Motor Overtemperature I2t

4


A0520 Rectifier Overtemperature

A0521 Ambient Overtemperature

A0522 I2C read out timeout

A0523 Output fault

A0535 Braking Resistor Output

A0541 Motor Data Identification Active A0541 Motor Data Identification Active

A0542 Speed Control Optimization Active

A0590 Encoder feedback loss warning

A0600 RTOS Overrun Warning A0600 RTOS Overrun Warning

A0700 - AO709 CB warning A0700 - AO709 CB warning

A0710 CB communication error A0710 CB communication error

A0711 CB configuration error A0711 CB configuration error

A0910 Vdc-max controller de-activated A0910 Vdc-max controller de-activated

A0911 Vdc-max controller active A0911 Vdc-max controller active

A0912 Vdc-min controller active

A0920 ADC parameters not set properly A0920 ADC parameters not set properly

A0921 DAC parameters not set properly A0921 DAC parameters not set properly

A0922 No load applied to inverter A0922 No load applied to inverter

A0923 Both JOG Left and JOG Right are

requested

A0923 Both JOG Left and JOG Right are

requested

A0952 Belt Failure Detected

A0936 PID Autotuning Active

5


ABB VFDs

ACS 350

WARNING Ignoring the following instructions can cause physical injury or death, or damage to

the equipment. Only qualified electricians are allowed to install and maintain the drive! Never work on the

drive, motor cable or motor when input power is applied. After disconnecting the input power, always wait

for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive,

motor or motor cable.

Before performing any maintenance activity, ensure by measuring with a multimeter (impedance at least 1

Mohm) that:

1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.

2. There is no voltage between terminals BRK+ and BRK- and the ground.

Do not work on the control cables when power is applied to the drive or to the external control circuits.

Externally supplied control circuits may carry dangerous voltage even when the input power of the drive is

switched off.

Do not make any insulation or voltage withstand tests on the drive.

If a drive whose EMC filter is not disconnected is installed on an IT system [an ungrounded power system

or a high resistance-grounded (over 30 ohms) power system], the system will be connected to earth potential

through the EMC filter capacitors of the drive. This may cause danger or damage the drive.

If a drive whose EMC filter is not disconnected is installed on a corner grounded TN system, the drive will

be damaged.

WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit

terminals U1, V1, W1 and U2, V2, W2 and BRK+ and BRK-

WARNING The drive is not field repairable. Never attempt to repair a malfunctioning drive;

contact your local ABB representative or Authorized Service Center for replacement. Make sure that dust

from drilling does not enter the drive during the installation. Electrically conductive dust inside the drive

may cause damage or lead to malfunction. Ensure sufficient cooling.

6


Operation and Start-up

Do not activate automatic fault reset functions if dangerous situations can occur. When activated, these

functions will reset the drive and resume operation after a fault.

Do not control the motor with an AC contactor or disconnecting device (disconnecting means); use instead

the control panel start and stop keys or external commands (I/O or fieldbus). The maximum allowed

number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is two per minute and

the maximum total number of chargings is 15 000.

If an external source for start command is selected and it is ON, the drive will start immediately after an

input voltage break or fault reset unless the drive is configured for 3 wire (a pulse) start/stop.

When the control location is not set to local (LOC not shown on the display), the stop key on the control

panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key LOC and

then the stop key.

Figure 5. ACS 350 Block Diagram

7


Table 4. Alarm and Fault Codes

8


9


10


11


12


13


14


15


16


ACH 550

WARNING The ACH550 adjustable speed AC drive should ONLY be installed by a qualified

electrician.

WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit

terminals U1, V1, W1 (L1, L2, L3) and U2, V2, W2 (T1, T2 T3) and, depending on the frame size, UDC+

and UDC-, or BRK+ and BRK-

WARNING Dangerous voltage is present when input power is connected. After disconnecting the

supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the

cover. Even when power is switched off from the input terminals of the ACH550, there may be dangerous

voltage (from external sources) on the terminals of the relay outputs.

WARNING When the control terminals of two or more drives are connected in parallel, the

auxiliary voltage for these control connections must be taken from a single source which can either be one

of the drives or an external supply. 1-4 ACH550-UH User’s Manual Safety

WARNING Disconnect the internal EMC filter when installing the drive on an IT system (an

ungrounded power system or a high-resistance-grounded [over 30 ohm] power system).

WARNING Do not attempt to install or remove EM1, EM3, F1 or F2 screws while

power is applied to the drive’s input terminals.

WARNING Do not control the motor with the disconnecting device (disconnecting means);

instead, use the control panel keys or commands via the I/O board of the drive. The maximum allowed

number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is five in ten minutes.

WARNING Never attempt to repair a malfunctioning ACH550; contact the factory or your local

Authorized Service Center for repair or replacement.

17


WARNING The ACH550 will start up automatically after an input voltage interruption if the

external run command is on.

Figure 6. Wiring Diagram ACH 550

18


Figure 7. Wiring Diagram ACH 550

19

Issue Date : 2011-09-30 Z - Refrigerant Pressure Table

Table 1. Pressure – Temperature Relation

Temperature [F]Pressure [psi g]

R-410a R-407c

18 75.2 34.8

22 82.3 39.1

26 89.7 43.6

30 97.5 48.4

34 105.7 53.4

38 114.4 58.9

42 123.6 64.6

46 133.2 70.6

50 143.3 77.1

55 156.6 106.0

60 170.7 116.2

65 185.7 127.0

70 201.5 138.5

75 218.2 150.6

80 235.9 163.5

85 254.6 177.0

90 274.3 191.3

95 295.0 106.4

100 316.9 222.3

105 339.9 239.0

110 364.1 256.5

115 389.6 274.9

120 416.4 294.2

125 444.5 314.5

130 474.0 335.7

135 505.0 357.8

140 537.6 380.9

145 571.7 405.1

150 607.6 430.3

155 645.2 456.6

1

Issue Date : 2011-09-30 Z - Startup Report

Startup Report - Seresco Technologies Inc.

Project Name NE Series Model

Location Serial Number

Site Contact/Tel: Seresco Rep.

Unit Visual Inspection

Check Comments

Supply air blowing on exterior doors and windows?

No supply-return air short-circuiting?

Outdoor air connected to Seresco unit?

Exhaust fan installed and operating, away from intake?

Vapor Barrier installed?

Condensate P-Trap installed and filled?

Condensate line tested?

Pool Water piping properly installed?

Auxiliary pool water circulating pump installed?

Pool water flow to spec?

OACC or Dry Cooler installed and wired properly?

Nameplate voltages verified?

Main disconnect installed?

Wiring connections checked & tightened?

Control wiring to aux pool heater installed?

Floor drain in mechanical room?

Chemicals stored in separate ventilated room?

Air balance report on file?

List other external controlled components

WebSentry connected?

Blowers, compressors rotation checked?

Adequate service access provided?

Unit’s leveled and vibration isolated?

Flex connectors used at both duct connections?

What type of refrigerant is used?

** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 ** 1 of 4

Z - Startup Report Issue Date : 2011-09-30

Unit Electrical Data

L1 – L2 L1 – L3 L2 – L3 Nameplate

Unit Voltage (V)

Transformer secondary voltage (V)

Compressor 1 (A)

Compressor 2 (A)

Main Blower 1 (A)

Main Blower 2 (A)

Exhaust Blower 1 (A)

Exhaust Blower2 (A)

Purge Blower 1 (A)

Purge Blower 2 (A)

OACC Motor 1 (A)

OACC Motor 2 (A)

OACC Motor 3 (A)

OACC Motor 4 (A)

Heat Recovery Pump (A)

Hot Water Pump (A)

Hot Water Pump 2(A)

NOTE: Put ALL additional info/comments into Notes section.

Outdoor Air Condensing / Cooling Unit inspection

Check Comments/Data

OACC or dry cooler located how feet above/below/level with

Seresco Unit?

Oil traps installed for OACC?

Model number of condenser

Field charge added in pounds and refrigerant type

Fluid GPM

Glycol %

Glycol stabilizers added?

Distance from Seresco Unit to OACC or dry cooler (one-way line length), ft

Hot gas line size (in)

Liquid line size (in)

Pipe size to dry cooler (in)

2 of 4 For tech support call: 1-770-457-3392 ext.2# OR 1-613-741-3603 ext.4#


Fluid Temperature entering main unit (F)

Fluid Temperature leaving main unit (F)

Piping and valves installed per spec?

Unit Operating Data and Configurations

Operating Data Unit Configuration

Sensor Reheat Reheat +

Pool heat

A/C A/C +

Pool heat

Setpoints Value

Return Air (F) Return Air (F)

Return Air (% RH) Return Air (RH)

Supply Air (F) Pool 1 (F)

Pool 1 In (F) Pool 2 (F)

Pool 1 Out (F) Purge (F)

Pool 2 In (F) HR (F)

Pool 2 Out (F) Economizer (F)

Outdoor Air (F)

Comp 1 HP (psi) Air Heating Type

Comp 1 LP (psi) Clock Set?

Comp 1 Suction (F) Board #

Comp 1 Discharge (F) MAC address

Evap 1 (F) IP address

Superheat 1 (F)

Comp 2 HP (psi) BACNET?

Comp 2 LP (psi) LON?

Comp 2 Suction (F) MODBUS?

Comp 2 Discharge (F)

Evap 2 (F)

Superheat 2 (F) NOTE: Check/verify superheat is within 18 – 22 F margin; refer to

Pressure -Temperature chart for proper refrigerant. Adjust if required.

Exhaust (F)

Reheat (F)

T/B Sight Glasess1

T/B Sight Glasses 2 NOTE: For Receiver Sight glasses:T(top)/B(bottom) make note whether

ball is “UP” or “DOWN”. Moisture Indicator 1

Moisture Indicator 2



Startup Date

Startup Company Name

Startup Company Contact #

Startup Technician Name

Startup Technician Contact #

Notes/Comments/Info



Startup Report - Seresco Technologies Inc.

Project Name NE Series Model

Location Serial Number

Site Contact/Tel: Seresco Rep.

Unit Visual Inspection

Check Comments

Supply air blowing on exterior doors and windows?

No supply-return air short-circuiting?

Outdoor air connected to Seresco unit?

Exhaust fan installed and operating, away from intake?

Vapor Barrier installed?

Condensate P-Trap installed and filled?

Condensate line tested?

Pool Water piping properly installed?

Auxiliary pool water circulating pump installed?

Pool water flow to spec?

OACC or Dry Cooler installed and wired properly?

Nameplate voltages verified?

Main disconnect installed?

Wiring connections checked & tightened?

Control wiring to aux pool heater installed?

Floor drain in mechanical room?

Chemicals stored in separate ventilated room?

Air balance report on file?

List other external controlled components

WebSentry connected?

Blowers, compressors rotation checked?

Adequate service access provided?

Unit’s leveled and vibration isolated?

Flex connectors used at both duct connections?

What type of refrigerant is used?



Unit Electrical Data

L1 – L2 L1 – L3 L2 – L3 Nameplate

Unit Voltage (V)

Transformer secondary voltage (V)

Compressor 1 (A)

Compressor 2 (A)

Main Blower 1 (A)

Main Blower 2 (A)

Exhaust Blower 1 (A)

Exhaust Blower2 (A)

Purge Blower 1 (A)

Purge Blower 2 (A)

OACC Motor 1 (A)

OACC Motor 2 (A)

OACC Motor 3 (A)

OACC Motor 4 (A)

Heat Recovery Pump (A)

Hot Water Pump (A)

Hot Water Pump 2(A)

NOTE: Put ALL additional info/comments into Notes section.

Outdoor Air Condensing / Cooling Unit inspection

Check Comments/Data

OACC or dry cooler located how feet above/below/level with

Seresco Unit?

Oil traps installed for OACC?

Model number of condenser

Field charge added in pounds and refrigerant type

Fluid GPM

Glycol %

Glycol stabilizers added?

Distance from Seresco Unit to OACC or dry cooler (one-way line length), ft

Hot gas line size (in)

Liquid line size (in)

Pipe size to dry cooler (in)



Fluid Temperature entering main unit (F)

Fluid Temperature leaving main unit (F)

Piping and valves installed per spec?

Unit Operating Data and Configurations

Operating Data Unit Configuration

Sensor Reheat Reheat +

Pool heat

A/C A/C +

Pool heat

Setpoints Value

Return Air (F) Return Air (F)

Return Air (% RH) Return Air (RH)

Supply Air (F) Pool 1 (F)

Pool 1 In (F) Pool 2 (F)

Pool 1 Out (F) Purge (F)

Pool 2 In (F) HR (F)

Pool 2 Out (F) Economizer (F)

Outdoor Air (F)

Comp 1 HP (psi) Air Heating Type

Comp 1 LP (psi) Clock Set?

Comp 1 Suction (F) Board #

Comp 1 Discharge (F) MAC address

Evap 1 (F) IP address

Superheat 1 (F)

Comp 2 HP (psi) BACNET?

Comp 2 LP (psi) LON?

Comp 2 Suction (F) MODBUS?

Comp 2 Discharge (F)

Evap 2 (F)

Superheat 2 (F) NOTE: Check/verify superheat is within 18 – 22 F margin; refer to

Pressure -Temperature chart for proper refrigerant. Adjust if required.

Exhaust (F)

Reheat (F)

T/B Sight Glasess1

T/B Sight Glasses 2 NOTE: For Receiver Sight glasses:T(top)/B(bottom) make note whether

ball is “UP” or “DOWN”. Moisture Indicator 1

Moisture Indicator 2



Startup Date

Startup Company Name

Startup Company Contact #

Startup Technician Name

Startup Technician Contact #

Notes/Comments/Info


________________________________________________

Issue Date : 2011-09-30

www.serescodehumidifiers.com Supersedes : 2011-09-20

Seresco Technologies Inc. has a policy of continuous product and product data improvement and reserves the right to change

design and specifications at any time without prior notification. Only qualified technicians working within their area of

competence should perform the installation and maintenance of equipment referred to in this literature.

Cover Page - NP Series - Seresco Dehumidifiers

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